Pallet Storage Rack Layout for Independent Dual-Cart Access

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Solution Overview

Problem

The existing storage rack design with two independently operating carts faces challenges in optimizing space utilization, as the vertical rack supports are spaced too far apart to allow both carts to move independently without interfering with each other, and modifying the rack to accommodate an upper cart requires increased space and material costs.

Innovation Solution

The upper cart is designed with a wider support structure that extends beyond the rack supports, allowing it to be moved on rails narrower than the pallets, while the pallet-receiving parts are narrower to fit between the supports, enabling independent movement of both carts without altering the rack's design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the vertical rack supports are spaced to allow pallets to move horizontally between them, then the rack can store and retrieve pallets efficiently, but there is insufficient space for a second cart to move independently without interfering with the first cart

Engineering Contradiction:

Improvepallet storage and retrieval efficiencyVSAvoidability to accommodate multiple independent carts

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The upper cart is segmented into two functional parts: a support structure (wider portion) that moves on rails outside the rack supports, and a pallet-receiving part (narrower portion) that fits between the rack supports. This segmentation allows each part to serve its specific function in the appropriate spatial zone, enabling independent operation of multiple carts without interference

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structure of the upper cart is positioned in a different spatial dimension (outside the rack supports) compared to the pallet-receiving part (between the rack supports). This dimensional separation allows both carts to operate independently in their respective zones, resolving the space conflict while maintaining efficient pallet handling capabilities

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If the rack supports are spaced farther apart to accommodate an upper cart with wider rails, then the upper cart can move independently, but the space utilization of the rack is reduced and material costs increase

Engineering Contradiction:

Improveindependent cart movement capabilityVSAvoidrack space utilization

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The upper cart's support structure is separated from its pallet-receiving function, allowing the support structure to use external rails while the pallet-receiving part utilizes the existing rack support spacing. This maintains optimal rack space utilization without requiring wider spacing between vertical supports

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

External rails are introduced as an intermediary element to support the upper cart's movement, eliminating the need to modify the rack support spacing. The rails act as a mediator that provides the necessary support structure clearance while preserving the compact rack configuration for optimal space utilization

Inventive Principle:

Principle #24Intermediary (Mediator)

3Area of stationary object

If the upper cart's support structure is made narrower to fit between rack supports, then space is optimized, but the cart cannot be moved on rails that are narrower than the pallets

Engineering Contradiction:

Improverack space utilizationVSAvoidcart movement on narrow rails

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The upper cart is divided into a support structure portion (for rail movement) and a pallet-receiving portion (for storage function). The support structure is positioned outside the rack supports to accommodate wider rails needed for stable cart movement, while the pallet-receiving part is positioned between the supports to optimize rack space utilization

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20100012608A1Storage racks

Publication Date: 2010.01.21 KEURO BESITZ & EDV DIENSTLEISTUNGS

AI summary

A storage rack having at least one shelf (1) with a number of storage spaces (4), arranged over top of each other, for pallets (5) held in the storage spaces (4) on vertical rack supports (2) and which can be horizontally removed sideways from the storage spaces (4). A rack operating device (7) removes and inserts pallets (5) into and out of the storage spaces (4), and a station cart (8) forms a lowermost storage space (4) to receive a pallet (5), and can be horizontally moved out of the rack (1) on a first pair of rails (12) located at a side of the rack (1) facing away from the rack operating device (7). An upper cart (9) is located above the station cart (8) and forms another one of the storage spaces (4) to receive a pallet (5) and is horizontally movable on a second pair of rails (13), which generally extend at a same height as the first pair of rails (12), and have a wider track and also lead out of the rack (1). The upper cart (9) includes a support structure (15, 16) at a side facing away from the rack operating device (7), having a greater clearance in an area of the station cart (8) which is larger than a length of the pallet (5), and which is provided with wheels (18) running on the second pair of rails (13), and parts (17, 20) of the upper cart not related to the support structure (15, 16) thereof can be inserted between the vertical rack supports (2) of the rack (1).