Modular Rack Assembly Using Detachable Floor Modules for Safe Access
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Solution Overview
Problem
Existing warehouse systems face inefficiencies in item storage and picking due to the need for large-scale equipment for rack assembly, which complicates the assembly process and requires significant resources.
Innovation Solution
A method for assembling a rack with detachable floor modules and support columns that allows for easy assembly without large-scale equipment, enabling operators to access lower floors safely and efficiently by forming a step-like route, and allowing the rack to be easily expanded or modified.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large-scale equipment such as scaffolds and aerial work platforms are used for rack assembly, then the structural stability and safety of high-rise rack assembly is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The rack structure is divided into modular floor modules that can be assembled incrementally. Each floor module is a self-contained unit that can be attached to support columns independently, allowing workers to assemble the rack floor by floor without requiring complete scaffolding structures for the entire height.
Solution Approach 2:
Floor modules are pre-assembled on the ground into complete floor units before being lifted and attached to the support columns. This preliminary assembly on stable ground eliminates the need for complex aerial work platforms during the main assembly process, as workers only need to perform simple attachment operations at each floor level.
2Stability of the object's composition
If traditional fixed rack assembly methods are used, then structural stability is ensured, but the ease of manufacture and assembly is reduced
Solution Approach 1:
The rack is segmented into detachable floor modules that can be manufactured separately and assembled in a standardized sequence. Each floor module contains integrated fastening mechanisms that simplify the attachment process to basic bolting operations, making assembly straightforward while maintaining structural integrity through the modular connection system.
Solution Approach 2:
The floor modules are designed as universal components that can be used across different rack configurations and heights. The standardized interface between floor modules and support columns allows the same module design to be reused throughout the entire rack structure, simplifying manufacturing while ensuring consistent structural performance.
3Strength
If complete floor modules are attached to all support columns, then structural integrity is maximized, but the ease of operation for maintenance and access is reduced
Solution Approach 1:
The floor module attachment system is designed to be dynamically adjustable. Floor modules can be quickly detached and reattached to support columns without requiring complete disassembly of the rack structure. This dynamic capability allows maintenance personnel to access specific floors by removing only the necessary floor modules while leaving the rest of the rack intact and structurally sound.
Solution Approach 2:
The modular floor design creates natural access points between modules. By segmenting the rack into discrete floor modules rather than continuous flooring, the system provides built-in access points that can be opened for maintenance while maintaining structural support through the remaining attached modules and support columns.
4Duration of action of stationary object
If the rack is designed as a fixed permanent structure, then long-term stability is ensured, but the adaptability for layout changes and expansion is reduced
Solution Approach 1:
The rack is constructed from standardized floor modules that can be easily added, removed, or reconfigured. This modular segmentation allows the rack to evolve over time - new floors can be added by attaching additional modules to existing support columns, and unused floors can be removed by detaching modules, providing long-term adaptability while maintaining structural stability through the proven modular connection system.
Solution Approach 2:
The attachment mechanisms for floor modules are designed to be reversible and reconfigurable. Floor modules can be detached and reattached to different support columns or positions without special tools or complex procedures, enabling the rack layout to be dynamically adjusted for changing storage needs while maintaining the same structural integrity as the original configuration.
Data Source
AI summary
A rack includes a plurality of floors each of which stores a plurality of bins for containing items, and allows a transportation robot to run along a surface thereof; and a plurality of support columns supporting the floors. Each of the floors includes a plurality of floor modules making up part of each of the floors, and each of the floor modules is detachably supported by the support column. This method for assembling a rack includes steps of: assembling each of the floors from a lower floor to an upper floor by attaching the floor module to the support column; and detaching the at least one floor module from the support column on each of the floors to secure a route for an operator to go down to the floor of the lower floor from the upper floor in the assembling step.