Multi-Level Storage Rails That Eliminate Warehouse Cross-Bracing
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Solution Overview
Problem
Traditional pallet load storage structures in automated warehouses are laterally unstable and require redundant diagonal supports, increasing material and labor costs while wasting space, as they are designed based on non-automated systems and lack structural rigidity for robotic vehicle rails.
Innovation Solution
The introduction of multi-level rails with angled supports and torsion-reinforced beams that eliminate the need for diagonal cross-bracing, providing structural integrity and allowing for compact, efficient storage structures with integrated vehicle support surfaces, and the use of reinforced flanges to resist torsional stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diagonal struts are added to traditional storage structures to provide lateral stability, then structural rigidity is improved, but material costs and labor requirements increase
Solution Approach 1:
The patent combines the rail structure with the support function by integrating vertical supports directly into the rail assembly. The rails are mounted on vertical support members that extend from the floor to the rail level, eliminating the need for separate diagonal bracing elements while maintaining structural rigidity through the integrated design.
Solution Approach 2:
The patent extracts and removes the unnecessary diagonal strut elements from the structure. By using vertical supports with rails mounted perpendicular to them, the design eliminates the harmful complexity of diagonal bracing while achieving the same lateral stability function through a simpler configuration.
2Extent of automation
If vehicle rails are added to traditional storage structures to enable automated vehicles, then automation capability is improved, but structural redundancy increases and space is wasted
Solution Approach 1:
The patent merges the rail function with the support structure by mounting rails directly on vertical support members. This integration eliminates redundant structural elements that would otherwise be needed to support the rails, achieving automation capability without unnecessary complexity or space waste.
Solution Approach 2:
The vertical support members serve multiple functions: they provide lateral stability, support the rails for automated vehicles, and act as structural columns. This multi-functionality eliminates the need for separate diagonal bracing and redundant support elements, achieving automation while maintaining structural efficiency.
3Ease of manufacture
If traditional storage structure design is used for automated warehouses, then construction simplicity is maintained, but structural rigidity for robotic vehicles is insufficient
Solution Approach 1:
The patent segments the structure into distinct vertical support members and horizontally mounted rails. This segmentation allows each component to be optimized for its specific function while maintaining overall construction simplicity. The vertical supports provide rigidity, and the rails provide vehicle guidance, with clear separation of functions.
Solution Approach 2:
Instead of adding rails to existing horizontal beams as in traditional structures, the patent inverts the approach by mounting rails perpendicular to vertical support members. This inversion creates a more rigid structure that better supports automated vehicles while maintaining construction simplicity through the straightforward vertical-to-horizontal mounting relationship.
Data Source
AI summary
A multi-level rail for a storage structure may comprise an upper horizontal portion configured to support a load and a lower horizontal portion configured to support a row vehicle. An upper support portion extends downward diagonally from the upper horizontal portion toward the lower horizontal portion, and a lower support extends downward diagonally from the lower horizontal portion. This rail is configured to connect to at least one vertical post of the storage structure. Support beams for a railed storage structure are also disclosed with an elongated body having a terminal end portion configured to attach to a vertical column of a storage support structure and an upper support surface configured to support a horizontal support rail. A wing portion is secured to the terminal end portion and configured to attach to the horizontal support rail by extending lateral to the elongated body and above the upper support surface.