Press-Locked Grating Assembly to Reduce Welding Cost and Monitoring
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Solution Overview
Problem
Existing press locked gratings for shelves are heavy and expensive due to high material costs, requiring constant monitoring of welding parameters for stability and load-bearing capacity, which can lead to weld seam failures if not properly regulated.
Innovation Solution
A press locked grating design where the first leg of the longitudinal profile is inserted into punched holes of cross members, with subsequent deformations preventing horizontal displacement, achieving a stable and cost-effective connection without the need for continuous welding parameter monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect longitudinal sides to cross members, then structural stability and load-bearing capacity are improved, but manufacturing complexity and cost increase due to constant monitoring of welding parameters
Solution Approach 1:
The patent replaces the welding process with a mechanical press connection system. Longitudinal sides are pressed into recesses of cross members, creating a mechanical joint that eliminates the need for welding operations and parameter monitoring, while maintaining structural integrity through friction and geometric interlocking
Solution Approach 2:
The press connection design allows the components themselves to create the connection without external monitoring systems. The longitudinal sides automatically engage with the cross members through the pressing action, and the connection self-regulates through the mechanical interface geometry, eliminating the need for continuous welding parameter monitoring
2Strength
If steel materials with high material costs are used, then load-bearing capacity is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the connection method parameter from welding to mechanical pressing, and modifies the cross member design by adding recesses with specific geometric parameters. This allows the use of standard steel profiles without requiring expensive high-strength materials, as the mechanical connection geometry provides the necessary load-bearing capacity
Solution Approach 2:
The recesses in the cross members are designed with specific local geometric features (width, depth, shape) that concentrate the connection forces in optimal locations. This local optimization of the connection geometry provides high load-bearing capacity at the connection points while allowing the rest of the structure to use standard, lower-cost materials
3Stability of the object's composition
If solid steel profiles are used for longitudinal sides and cross members, then structural stability is improved, but weight increases
Solution Approach 1:
The patent segments the cross members by introducing recesses that create localized voids or reduced-material zones. This segmentation allows the structure to maintain stability through the distributed network of connection points while reducing overall material usage and weight compared to solid profiles throughout
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design results in a lighter, more cost-effective grating with maintained structural stability and load-bearing capacity, allowing for reduced material costs and improved durability by minimizing the shadowing effect for extinguishing media passage during fires.
Implementation Method 1
the first leg of the profile of the longitudinal sides is inserted or pressed into the punched hole
Implementation Method 2
by the subsequent introduction of deformations to the right and left of the cross member, preferably immediately adjacent to it, in the first leg of the profile of the longitudinal sides, a horizontal displacement of the components against each other is prevented
Data Source
AI summary
A press locked grating, in particular for use as a shelf for plate or heavy-duty shelves, has two longitudinal sides and cross members and longitudinal members having an I-shaped profile arranged between the longitudinal sides and at right angles to each other. The longitudinal members are inserted or pressed into punched holes of the cross members open towards the grating upper side. The longitudinal sides are formed in cross-section as a profile that includes at least first and second orthogonal legs. Each cross member has a punched hole at each end, in which the first leg is arranged and firmly connected thereto by a connecting method. The first leg is inserted or pressed into the punched hole, thereby achieving a first connection of the profile to the cross member, and has at least one deformation, thereby fixing the insertion or press connection of the cross member to the profile.