Interchangeable base steel structure storage assembly
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Solution Overview
Problem
Current storage racking systems in warehouses and distribution centers face high damage rates from material handling equipment, leading to costly and time-consuming repairs, especially due to the vulnerability of roll-form columns and the need for frequent replacement of damaged components, which disrupts storage capacity and safety.
Innovation Solution
A base steel structure assembly with bolted connections and structural members is designed to support the racking system, allowing for quick replacement of damaged components without dismantling the entire system, using heavier structural materials for the base and lighter gauge materials above, with features like welded tabs and a load jack for efficient repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If roll-form columns are used for storage racking systems, then ease of manufacture and cost are improved, but reliability and resistance to damage deteriorate
Solution Approach 1:
The storage racking system is divided into modular components (columns, beams, braces) that can be independently replaced. The bolted connection system enables segmentation of the structure into replaceable units, allowing damaged roll-form columns to be swapped without affecting the entire system.
Solution Approach 2:
The patent changes the connection parameter from welded (permanent) to bolted (reversible), enabling easy replacement of damaged components. This parameter change allows the system to maintain reliability by replacing damaged roll-form columns while preserving the ease of manufacture advantage.
2Ease of operation
If lighter duty roll-form systems are used, then ease of operation and cost are improved, but strength and resistance to impact deteriorate
Solution Approach 1:
The system incorporates protective measures in advance, such as positioning columns away from high-impact zones and designing the bolted connection system to allow quick replacement before damage propagates. This preliminary preparation enables lighter materials to be used while maintaining operational safety.
Solution Approach 2:
The patent accepts that lighter roll-form columns may be damaged and designed them as replaceable components rather than permanent structures. The bolted connection system enables quick replacement of damaged columns, making the system tolerant of using lighter, more vulnerable materials.
3Productivity
If clear working aisles are reduced to optimize storage density, then storage capacity is improved, but the risk of MHE contacting and damaging racking increases
Solution Approach 1:
The system uses bolted connections as a form of protective design, allowing the structure to absorb impact damage without catastrophic failure. The reversible connections enable quick replacement of damaged components, cushioning the system against the increased damage risk from tighter aisles.
Solution Approach 2:
The bolted connection system enables the racking structure to be self-repairing through quick replacement of damaged components. This self-service capability allows the system to withstand higher damage rates from reduced aisle clearance without requiring extensive downtime for repairs.
4Reliability
If damaged columns are replaced by dismantling and reassembling the entire rack, then reliability is restored, but loss of time and productivity increase
Solution Approach 1:
The racking system is segmented into independently replaceable components connected by bolts. This segmentation allows damaged columns to be replaced without dismantling the entire structure, significantly reducing repair time while maintaining structural integrity.
Solution Approach 2:
The bolted connection system transforms the static, permanent welded structure into a dynamic, reconfigurable system. This dynamic connection method enables quick assembly and disassembly of individual components, allowing rapid replacement of damaged columns without time-consuming complete dismantling.
Data Source
AI summary
A storage rack assembly includes a base steel structure which is interchangeably connected to the storage rack above. The base steel structure assembly is compromised of structural material with bolted connections which allow for the replacement or changing of damaged material due to accidental forklift contact all while the above storage system stays in place.