Mobile Rack Assembly Template for Precise Barrel Warehouse Framing
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Solution Overview
Problem
The existing methods for constructing lattice-work support frames for barrels in warehouses are inefficient due to high material waste, labor costs, and the need for skilled labor, as well as the challenges of working in varying temperature and humidity conditions, especially during warehouse expansions.
Innovation Solution
A mobile construction template system featuring a trailer with vertically extending members and horizontal tabs for precise positioning and attachment of beams, allowing for efficient assembly of lattice segments outside the warehouse, which can be relocated and used in remote locations, reducing labor requirements and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If skilled carpenters manually assemble lattice-work inside the warehouse, then the racks are constructed in proper form with correct fit and spacing, but the labor costs are high and construction time is excessive
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete lattice segments on a mobile construction template outside the warehouse before installing them inside. The template pre-positions all vertical and horizontal members with precise spacing and alignment, allowing segments to be constructed in advance under controlled conditions rather than assembling piece-by-piece inside the warehouse during installation.
Solution Approach 2:
The patent divides the lattice structure into modular segments that can be independently constructed on the mobile template and then installed as complete units inside the warehouse. Each segment contains multiple vertical and horizontal members already assembled together, transforming the construction process from individual piece assembly to modular unit installation.
2Manufacturing precision
If individual lattice elements are constructed piece by piece inside the warehouse, then proper orientation and spacing can be achieved, but material waste increases due to on-site cutting and fitting
Solution Approach 1:
The mobile construction template enables preliminary cutting, sizing, and assembly of lattice members outside the warehouse where materials can be optimally utilized. All cutting and fitting operations are completed in advance on the template, eliminating on-site waste generation during warehouse installation.
Solution Approach 2:
The template serves as a reusable master pattern that can be used to construct multiple identical lattice segments. Once the template is built, it can produce numerous copies of properly proportioned lattice members without requiring additional measurement and cutting operations for each piece, reducing material waste through consistent replication.
3Manufacturing precision
If skilled laborers work inside the warehouse during expansion, then the lattice-work can be properly assembled, but the work is disrupted by temperature and humidity conditions inside the warehouse
Solution Approach 1:
The patent moves the construction activity outside the warehouse environment by pre-assembling lattice segments on a mobile template in controlled outdoor or shop conditions. This eliminates exposure to warehouse temperature and humidity variations during the critical assembly phase, while still achieving precise fit and alignment through the template's fixed positioning features.
Solution Approach 2:
The mobile construction template acts as an intermediary device that transfers the lattice assembly process from the harmful warehouse environment to a controlled external environment. The template itself becomes the workspace, allowing construction to occur outside the warehouse while maintaining precision through the template's structured guidance system.
4Stability of the object's composition
If manual construction methods are used for warehouse expansion, then the existing warehouse structure is preserved, but the construction process causes significant disruption to storage operations
Solution Approach 1:
The patent divides the lattice structure into modular segments that can be pre-assembled outside and quickly installed inside the warehouse. This modular approach allows construction to proceed in discrete units rather than requiring the entire warehouse to be shut down for prolonged piece-by-piece assembly, minimizing operational disruption.
Solution Approach 2:
By pre-assembling complete lattice segments outside the warehouse before installation, the construction process is condensed into a rapid installation phase inside the warehouse. This eliminates prolonged on-site construction activities that would disrupt storage operations, as the majority of construction work occurs in advance in a non-operational area.
Data Source
AI summary
A construction template mounted on a mobile platform. The template is useful in the assembly of racks made for storing barrels, typically barrels of distilled spirits in a warehouse. Beams that will be joined to form a rack are placed alongside upright positioning elements of the construction template. Beams are placed horizontally held by tabs on the construction template. Then the upright and horizontal beams are joined to form a rack assembly that is lifted and moved off the platform.