Rack Cross Bar Locking Assembly for Stable Shelf Support
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Solution Overview
Problem
Existing shelf-type storage rack systems face issues with structural instability due to movement and misalignment of deck beams and cross bars, leading to potential load collapse and increased construction costs, along with difficulties in assembly and disassembly, especially on uneven floors with positional variations.
Innovation Solution
The improved storage rack system incorporates cross bars with flanges that overlap deck beams, featuring a tab for secure engagement and a stabilizer arm to prevent rolling, allowing for easy removal and reattachment, ensuring stable load support while accommodating positional variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If deck beams and cross bars are rigidly connected using welding or bolting, then structural strength is improved, but ease of assembly and disassembly deteriorates
Solution Approach 1:
The connection system is divided into separate modular components: deck beams with integrated connection elements, cross bars with matching engagement features, and optional stabilizer arms. This segmentation allows the structure to be assembled and disassembled in sections without requiring welding or bolting, while maintaining structural strength through the interlocking geometry of the components.
Solution Approach 2:
The patent introduces connection elements as intermediary components between deck beams and cross bars. These intermediaries include engagement features such as tabs, slots, and stabilizer arms that facilitate easy assembly and disassembly while providing rigid structural connection when assembled, eliminating the need for welding or bolting.
2Ease of manufacture
If traditional wooden slats are used between deck beams, then manufacturing cost is reduced, but reliability deteriorates due to slats being knocked-out or misaligned
Solution Approach 1:
The deck beams are pre-formed with integrated connection elements such as tabs, slots, or engagement features during manufacturing. This preliminary action ensures that when cross bars or stabilizer arms are installed, they automatically achieve proper alignment and secure positioning without requiring additional field operations, thereby maintaining reliability while keeping manufacturing costs low.
Solution Approach 2:
The patent introduces stabilizer arms and connection elements as intermediary components between deck beams and cross bars. These intermediaries provide automatic alignment and secure engagement, preventing the cross bars from being knocked out or misaligned, while adding minimal cost to the overall structure.
3Ease of operation
If cross bars are designed to be easily removable and reusable, then ease of operation is improved, but structural stability deteriorates
Solution Approach 1:
The connection system is designed with dynamic characteristics, allowing cross bars to be easily inserted and removed when needed, while automatically providing stable structural connection when assembled. The engagement features such as tabs and slots create a rigid connection during use, yet allow for simple disassembly when reconfiguration is required.
Solution Approach 2:
Stabilizer arms and connection elements serve as intermediaries that provide secure engagement between cross bars and deck beams. These intermediaries create friction-based or geometric interlocking connections that are sufficiently rigid to maintain structural stability during use, yet allow for easy removal when needed without requiring tools or complex disassembly procedures.
Data Source
AI summary
A storage rack system is provided that includes an improved cross bar attachment to create the framing for storage shelves. The cross bars are locked or secured against undesired movement and rolling to create a shelf that properly supports loads. The cross bars extend between the deck beams such that flanges at the ends thereof overlap the top of the deck beams. The flanges include a tab that extends downwardly to engage with an opening on the top of the deck beams. The lateral support further includes a stabilizer that is fastened to the side wall of the deck beams to prevent rolling or dislodgement of either member.