Press-Locked Grating With Profiled Deformation Joints to Reduce Weight
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Solution Overview
Problem
Existing press grates for panel and heavy-duty racks are heavy and costly due to their design requirements for high load capacity and stability, leading to increased material costs and potential welding issues that affect durability.
Innovation Solution
Introducing deformations next to the plug or press connection between the cross members and the longitudinal sides of the press grate, using a positive or non-positive connection method to secure the components, reduces the need for constant monitoring and regulation of welding parameters, and allows for a lighter and cheaper construction without compromising stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel materials are used for longitudinal sides and beams to guarantee stability and load-bearing capacity, then the structural strength is improved, but the weight of the grating increases
Solution Approach 1:
The grating is divided into modular components (longitudinal sides with profiles, crossbeams, and infill bars) that can be separately manufactured and assembled. This segmentation allows optimization of each component's weight-strength ratio while maintaining overall structural integrity through the connection system.
Solution Approach 2:
The invention uses composite construction combining steel profiles with strategic void spaces, creating a structure that maintains load-bearing capacity while reducing material usage. The profiled longitudinal sides with integrated connection elements create a composite system that distributes loads efficiently.
2Strength
If high load-bearing capacity is ensured through solid steel construction, then the stability is improved, but the material costs increase
Solution Approach 1:
By segmenting the structure into optimized components rather than using solid steel throughout, material is placed only where structurally necessary. The profiled longitudinal sides and selective infill bar placement reduce total material consumption while maintaining load-bearing capacity through efficient load distribution.
Solution Approach 2:
The structure implements local quality by providing full material density only in critical load-bearing areas (profiles and connection points) while using reduced material in non-critical areas (infill regions). This localized material distribution optimizes the strength-to-cost ratio.
3Strength
If welding connections are used to join crossbeams and longitudinal sides, then the connection strength is improved, but the manufacturing complexity and monitoring requirements increase
Solution Approach 1:
The welding process is extracted and replaced with mechanical connection systems (profiles with integrated connection elements, recesses, and bearing surfaces). This removes the complexity of welding parameter monitoring and regulation while maintaining connection strength through precision-machined mechanical interfaces.
Solution Approach 2:
The invention replaces the thermal welding process with a mechanical connection system based on profiles, recesses, and bearing surfaces. This mechanical system eliminates the need for continuous monitoring and regulation of welding parameters, simplifying manufacturing while maintaining connection integrity.
4Strength
If solid steel construction is used to ensure stability, then the load-bearing capacity is improved, but the open areas for extinguishing agent penetration are reduced
Solution Approach 1:
The grating is segmented into an open framework of profiled longitudinal sides and crossbeams with selectively placed infill bars, creating maximum open areas for extinguishing agent penetration. This segmented structure maintains load-bearing capacity through the strength of the profiled components and their connections while minimizing material blocking of spray paths.
Solution Approach 2:
Solid steel construction is applied locally only where structurally necessary (profiles and connection zones), while large open areas are maintained in the infill regions for extinguishing agent penetration. This local differentiation of material density optimizes both structural performance and fire safety requirements.
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
This approach results in a more stable and cost-effective press grate with reduced material costs and weight, maintaining the required load-bearing capacity while allowing extinguishing media to pass through effectively in case of a fire.
Implementation Method 1
the first leg of the profile is arranged in each punching and is firmly connected to it by a connection method
Implementation Method 2
by subsequently introducing deformations to the right and left of the crossbeam, preferably directly next to it, into the first leg of the profile of the longitudinal sides, a horizontal displacement of the components against each other is prevented
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The present invention relates to a press-locked grating (1), in particular for use as a shelf for panel storage racks or heavy-load racks, having two longitudinal sides (2a, 2b) and also transverse members (3) and longitudinal members (4), which are arranged between the longitudinal sides (2a, 2b), wherein the transverse members (3) and the longitudinal members (4) have an I-shaped profile, wherein the longitudinal members (4) are plugged or pressed into punched formations (3a) in the transverse members (3), said formations being open in the direction of the upper side of the press-locked grating, wherein the longitudinal members (4) and the transverse members (3) are arranged at right angles to one another, and wherein the longitudinal sides (2a, 2b), as seen in cross-section, are designed in profile form, wherein the profile comprises at least a first limb (ZI, UO) and a second limb (Z3, U1), which is arranged substantially at right angles to the first limb (ZI, UO), wherein, at each end (B1, E2), each of the transverse members (3) has a punched formation (4c), in which the first limb (ZI, UO) of the profile is arranged and is fixed to the same using a connecting method. In order to provide a press-locked grating (1) which is more lightweight, and can be produced more easily and with less monitoring, than the previously known prior art, without any reduction in structural stability and load-bearing capacity, it is proposed, within the context of the invention, that the first limb (ZI, UO) of the profile should be plugged or pressed into the punched formation (4c), this achieving a first connection between the profile and the transverse member (3), and that the first limb (ZI, UO) of the profile should have at least one deformation (VI, V3), this resulting in the plug-fit or press-fit connection between the transverse member (3) and the profile being fixed. This makes it possible for an extremely stable press-locked grating (1) to be manufactured quickly and cost-effectively.