Modular pallet repair kit and method of use thereof
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Solution Overview
Problem
Existing pallet rack repair kits require on-site welding, extensive inventory of replacement parts, and complete unloading of pallets, making them inefficient and costly for repairing damaged pallet rack frames.
Innovation Solution
A modular repair kit with customizable replacement posts of variable length, which can be cut to size, and assembled mechanically without welding, using a base with anchors and connecting members to secure the post to the floor and undamaged uprights, allowing for efficient and robust repairs without impacting the frame's load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional repair kits are used, then the pallet rack can be repaired, but on-site welding is required which increases complexity and time
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical connection system consisting of a replacement post, base plate, and connecting members that attach to the undamaged portions of the upright post through holes and fasteners, eliminating the need for on-site welding equipment and procedures
2Reliability
If traditional repair kits are used, then structural damage can be addressed, but extensive inventory of replacement parts is needed
Solution Approach 1:
The replacement post is designed as a universal component that can be cut to various lengths and configured for different repair scenarios. The single modular unit with adjustable length and standardized connection interfaces can address multiple damage locations and types, eliminating the need to maintain extensive inventories of various specialized replacement parts
3Ease of repair
If traditional repair kits are used, then damaged posts can be replaced, but complete unloading of pallets is required
Solution Approach 1:
The repair system is segmented into modular components (base plate, replacement post, connecting members) that can be installed independently. The connecting members attach to undamaged portions of the upright post above the damage area, allowing the repair to proceed while pallets remain on the rack, thus avoiding complete unloading
4Ease of manufacture
If pre-welded kits are used, then installation is simplified, but the existing pallet rack must be modified to precise lengths
Solution Approach 1:
The replacement post is designed with dynamic adaptability - it can be cut to the specific length required for each repair location. The modular design with standardized connection interfaces allows the same basic component to accommodate various configurations and lengths, eliminating the need for pre-welding and precise pre-cutting while maintaining ease of installation
Data Source
AI summary
A modular repair kit for repairing damaged pallet rack frames and a method of installation thereof which incudes modular elements that can be customized by mechanical process such as cutting, drilling and connecting, for example, by bolts, that avoids major modifications, such as welding, at the installation site. The modular repair kit utilizes a standard replacement post assembly that can be cut to fit into nearly any size gap that is created when the damaged portion of the pallet rack frame is removed. The remaining elements of the repair kit can then be customized to accommodate any size of the standard replacement post assembly.