Modular Shelf Structure With Self-Aligning Modules for Faster Assembly
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Solution Overview
Problem
Material handling systems face challenges such as complex and labor-intensive installation processes, vibration-induced issues, reduced storage capacity due to support posts, and vibration transfer to automated vehicles, especially in multilevel systems with autonomous vehicles.
Innovation Solution
A modular shelving structure with interchangeable modules featuring precision location features and alignment pins, allowing for adjustment-free assembly and alignment, reducing vibration and increasing storage density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional storage units are constructed with posts and bolted components, then structural stability is achieved, but installation becomes labor intensive and time consuming
Solution Approach 1:
The storage unit is divided into modular components (base, shelves, posts) that can be independently manufactured and assembled. The base is segmented into multiple base portions with corresponding apertures and protrusions that facilitate quick connection to posts, eliminating the need for complex bolting operations while maintaining structural stability.
Solution Approach 2:
The components are designed with self-aligning features including apertures, protrusions, and recesses that automatically guide proper positioning during assembly. The shelves have front and rear portions with corresponding features that self-align with posts, eliminating the need for manual measurement and adjustment during installation.
2Strength
If traditional storage units use posts to support shelves, then structural support is provided, but storage capacity is reduced due to space occupied by posts
Solution Approach 1:
The post structure is extracted and replaced with a cable support system. Cables are tensioned between anchor points on the base to provide shelf support, eliminating the need for vertical posts that occupy storage space. This allows shelves to extend closer together and maximizes the usable storage volume within the same footprint.
Solution Approach 2:
The support mechanism transitions from a vertical post-based system to a horizontal cable-based system. By moving the support function to the horizontal plane through tensioned cables anchored at base corners, the vertical space previously occupied by posts is freed for storage purposes.
3Ease of manufacture
If relaxed dimensional tolerances are used in component assembly, then manufacturing is easier, but vibration is induced to automated vehicles travelling on the structure
Solution Approach 1:
The mechanical connection system using bolts and rigid joints is replaced with a tension-based cable system. The cables are tensioned to specific forces that create a rigid, vibration-dampening structure. This substitution maintains ease of manufacture through simple cable attachment while eliminating vibration issues through the inherent damping characteristics of tensioned cables.
Solution Approach 2:
The structure combines different materials and connection methods: cable materials selected for specific tension properties, base materials providing rigid anchor points, and shelf materials that bridge between cable support points. This composite approach allows each component to be manufactured with standard tolerances while the assembled structure achieves high precision and low vibration.
4Manufacturing precision
If complex alignment and adjustment procedures are used post-assembly, then precise alignment is achieved, but installation time increases
Solution Approach 1:
Alignment features (apertures, protrusions, recesses) are pre-configured on all components during manufacturing. The base portions have pre-positioned anchor points, and shelves have pre-configured front and rear portions with corresponding alignment features. This preliminary configuration eliminates the need for post-assembly measurement and adjustment, achieving precise alignment through the designed-fit features.
Data Source
AI summary
A bot-shelf structure for an automatic store and retrieval system having store racks and self-navigating automatic robots, the bot-shelf structure includes an array of the store racks, a first type of structure module that defines a module part of the array, the assembly having more than one of the first type of structure module, each of which is interchangeable with each other, and has an integral structural datum feature determining a predetermined bot traverse reference level of each level of the array. A second type of structure module connected to the first type of structure module, where the second type of structure module has control features having a predetermined relationship with the integral structural datum feature of the first type of structure module, the control features being configured so that each second type of structure module is interchangeable with each other second type of structure module.