Warehouse Rack Upright Repair Device
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Solution Overview
Problem
Existing methods for repairing damaged warehouse rack uprights are time-consuming and costly, requiring disassembly and reassembly of racks, as existing clamping tools are unsuitable for bending back multiple corner parts of rack uprights and lack sufficient pressure force.
Innovation Solution
A device comprising an outer template adapted to the outer surface and an inner template adapted to the inner surface of the upright, with pressing means to bend the upright back into its original position, allowing for simultaneous bending of two or more corner parts without disassembling the rack, using a yoke and hydraulic or pneumatic pressure cylinder for precise adjustment and force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If existing clamping tools are used to bend back the upright profile, then the tool structure is simple, but insufficient pressure force is generated and only one corner part can be treated at a time
Solution Approach 1:
The device divides the pressing function into multiple independent pressing units (first pressing unit, second pressing unit, etc.), each capable of applying pressure to different corner parts of the profile simultaneously. This segmentation allows multiple pressing points to be activated independently, generating sufficient total pressure force while maintaining manageable device complexity through modular design
Solution Approach 2:
The pressing units are integrated within the template structure, where the pressing means are arranged inside the enclosed space formed by the template. The template itself encloses the profile while the pressing units nest within this enclosure, allowing the pressing mechanism to be compact yet powerful enough to generate the required pressure force
2Reliability
If the rack is emptied and disassembled to replace the damaged upright, then a new upright can be installed, but the procedure is very time-consuming and entails high costs
Solution Approach 1:
The device enables the upright profile to be repaired in situ without requiring removal from the rack structure. The profile is bent back to its original shape using the template and pressing units, allowing the upright to restore its structural strength while remaining in position, thus eliminating the time-consuming disassembly and reassembly process
Solution Approach 2:
The template is designed to enclose and support the profile in its correct original position before pressing begins. By pre-positioning the template against the outer surface and arranging the pressing units within the enclosed space, the device prepares the structural framework in advance, enabling immediate bending back action that restores structural strength without requiring preliminary disassembly
3Productivity
If existing clamping tools are used, then the device structure is simple, but it is only possible to treat one corner part of the profile at a time
Solution Approach 1:
The device incorporates multiple independent pressing units (first pressing unit, second pressing unit, third pressing unit, etc.), each capable of being activated independently to press different corner parts of the profile. This segmentation enables simultaneous treatment of multiple corner parts, significantly improving repair efficiency while the modular nature of the pressing units keeps device complexity manageable
Solution Approach 2:
The template structure is designed to accommodate multiple pressing units that can address different corner parts of the profile. The template encloses the entire profile and provides structural support for multiple pressing operations simultaneously, making the device universal enough to handle various damage locations without requiring separate tools for each corner part
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
Restores or significantly improves the structural strength of the upright without emptying or disassembling the rack, enabling rapid and efficient repair, with tests showing only slight reduction in structural strength and sometimes exceeding original strength after repair.
Implementation Method 1
using a yoke and hydraulic or pneumatic pressure cylinder for precise adjustment and force application
Implementation Method 2
using a yoke and hydraulic or pneumatic pressure cylinder for precise adjustment and force application
Data Source
AI summary
The present invention relates to a device (6) and method for repairing an upright profile (2) which has been bent out of an original position, in particular a profile of a warehouse rack upright for mounting of warehouse rack girders (3), wherein an inner space (13) accessible from an open side is defined in the profile. The device comprises an outer template (7) adapted to the form of the outer surface of the profile, an inner template (16,17) adapted to the form of the inner surface, wherein during use the inner template is arranged in the inner space of the profile via the open side, and pressing means for pressing the outer template against the outer side of the profile and pressing the inner template against the inner side of the profile with pressing force such that the upright profile is bent back into its original position.