Unit Load Rack Support Profile With Locked Front Vertical Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing general cargo warehouse designs require high accuracy in forklift positioning for storage and retrieval, are resource-intensive in manufacturing and assembly, and can be laterally unstable due to support profile geometry.
Innovation Solution
The design incorporates form-fitting slots and tabs on the front traverse to securely lock the vertical support in place, eliminating the need for additional vertical supports at the rear, allowing for simplified assembly and reduced material usage, with a rear traverse positioned higher than the front to enhance stability and storage depth control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the support profile is arranged higher than the upper edge of the traverse to allow transport fork insertion, then the accuracy requirements for forklift positioning are reduced, but the material usage increases and lateral stability decreases
Solution Approach 1:
The support structure is divided into a support profile and a separate vertical support element. The vertical support acts as an extension that provides the necessary height without requiring the entire support profile to be taller, thus reducing material usage while maintaining the required clearance for transport fork insertion.
Solution Approach 2:
Instead of increasing the profile height in the vertical dimension only, the solution adds a vertical support element that extends from the traverse upward to the support profile. This dimensional approach allows the support profile to be positioned higher without proportionally increasing material consumption across the entire structure.
2Ease of operation
If the support profile has a large profile height to allow transport fork insertion, then the clearance for fork insertion is sufficient, but the structure becomes laterally unstable
Solution Approach 1:
The lateral stability function is separated from the support profile and assigned to the vertical support element. This segmentation allows the support profile to maintain its optimal width-to-height ratio for stability while the vertical support provides the necessary height clearance for transport fork insertion without compromising lateral stability.
3Stability of the object's composition
If additional vertical supports are added to the rear to enhance stability and control storage depth, then the structural stability improves, but the device complexity and assembly effort increase
Solution Approach 1:
The function of the rear vertical support is extracted and integrated into the vertical support element at the front. This single vertical support performs multiple functions: providing height clearance for fork insertion, enhancing structural stability, and limiting storage depth through its positioning relative to the support profile.
Solution Approach 2:
The vertical support element is designed as a multi-functional component that simultaneously provides structural stability, controls storage depth, and enables transport fork insertion. This universal approach eliminates the need for separate rear vertical supports, reducing assembly complexity while maintaining all necessary functions.
4Ease of operation
If the front support is arranged higher than the rear support to allow transport fork insertion, then the clearance for fork insertion is sufficient, but the manufacturing precision requirements increase
Solution Approach 1:
The vertical support element is designed with self-aligning features that allow it to automatically position itself relative to the traverse and support profile during assembly. This self-service mechanism reduces the need for high-precision manufacturing and manual adjustment, as the component finds its correct position through its own geometric features.
Data Source
AI summary
A unit load storage system is proposed, consisting of vertical main supports (1), front and rear crossbeams (2, 3) arranged transversely to the storage and retrieval direction and attached to the main supports (1), and at least one support profile (10) extending in the storage and retrieval direction and vertically supported relative to the front crossbeam (2). The upper surface (11) of this support profile is located in a plane higher than the upper edge of the front crossbeam (2) and forms a support for the respective unit load. The front crossbeam (2) is provided with positive locking structures (21, 29) to fix the vertical support of the support profile (10) at least in the longitudinal direction of the crossbeam.To create a unit load storage system that requires minimal assembly effort and does not place excessive demands on the precise vertical positioning of a forklift or stacker crane used for storage and retrieval, the support profile (10) is vertically supported by a column (20). Its upper end is connected to the support profile (10). The lower end (22) is designed to engage with the positive locking structures (21, 29) of the front crossbeam (2).