Modular Pallet Rack Post Repair Without On-Site Welding
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Solution Overview
Problem
Existing pallet rack repair kits require on-site welding, extensive unloading of pallets, and a large inventory of replacement parts, and do not provide a modular solution for replacing damaged posts without compromising the structural integrity or impact capacity of the pallet rack.
Innovation Solution
A modular repair kit that includes a replacement post with an upper and lower section of indeterminate length, a reinforcement channel, and a base with anchors to secure the post to the floor, allowing for mechanical assembly without welding, and a method to evaluate and cut damaged sections for precise replacement without affecting the remaining frame's structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If existing pallet rack repair kits are used, then structural damage 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 repair kit assembly that includes a base plate, upright post, and cross members that mechanically interlock with the existing rack structure through pre-drilled holes and fasteners, eliminating the need for on-site welding
Solution Approach 2:
The repair kit is divided into separate modular components (base plate, upright post, cross members) that can be individually transported, positioned, and assembled at the repair site without requiring welding equipment or specialized skills
2Ease of repair
If existing repair methods are used, then damaged posts can be replaced, but extensive unloading of pallets is required
Solution Approach 1:
The repair kit components are pre-assembled and pre-positioned to fit within the space occupied by the damaged post, allowing the repair to be installed without removing the cross members or unloading the pallets that rest on the rack structure
Solution Approach 2:
The repair kit assembly is designed to nest within the existing rack structure, with the upright post fitting between existing cross members and the base plate securing to the floor, allowing repair installation without disrupting the loaded rack
3Ease of repair
If standard replacement parts are used, then repairs can be made, but a large inventory of parts is required
Solution Approach 1:
The repair kit uses standardized components with dimensions and connection interfaces that match common pallet rack specifications, allowing the same kit design to repair multiple different rack configurations and reducing the need for specialized inventory for each rack type
Solution Approach 2:
The repair kit components are designed with adjustable parameters such as variable post lengths and configurable cross member positions that can accommodate different rack configurations without requiring multiple specialized part variants
4Ease of repair
If damaged sections are cut and spliced, then repairs can be made, but precise cutting is required which increases manufacturing complexity
Solution Approach 1:
The repair kit components are pre-manufactured to precise specifications in a controlled factory environment, eliminating the need for precise on-site cutting and splicing operations that would require specialized equipment and skilled operators
Solution Approach 2:
Instead of attempting to salvage and splice damaged post sections, the invention uses pre-manufactured replacement posts that are designed to be installed as complete units, simplifying the repair process and eliminating the need for precise cutting operations
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.