Racking Beam Dual-Layer Coating for Welded Galvanized Steel
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Solution Overview
Problem
Existing shelving unit beams made from galvanized steel face challenges in achieving efficient and durable welds due to the surface layer formed by galvanizing, requiring bolted connections instead, which complicates production and increases costs.
Innovation Solution
A beam construction method where a primary protective layer, such as galvanizing, covers the entire surface except for a limited welding area, allowing welding of brackets to the strut, followed by a secondary varnish layer applied only to the welding area post-welding, ensuring oxidation resistance and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanized steel is used for struts and brackets, then oxidation resistance is improved, but welding quality deteriorates
Solution Approach 1:
The patent applies different protective treatments to different parts of the same component: galvanizing is applied to the entire surface except for localized welding areas where the zinc coating is intentionally omitted or removed to expose bare steel for proper welding. This local differentiation resolves the contradiction by providing oxidation resistance where needed while ensuring welding quality at connection points.
Solution Approach 2:
The protective coating is segmented into two distinct zones: a galvan化的 protective layer covering most of the surface for oxidation resistance, and an unprotected welding zone allowing proper weld penetration and strength. This segmentation allows each zone to fulfill its specific function without compromising the other.
2Reliability
If complete varnishing is applied to protect welded beams, then oxidation resistance is improved, but production time and cost increase
Solution Approach 1:
Instead of applying varnish to the entire beam surface, the patent applies it only partially to specific areas that require additional protection after welding. This partial action reduces varnishing time and cost while maintaining sufficient oxidation resistance through the pre-applied galvanizing on the majority of the surface.
Solution Approach 2:
The galvanizing is applied in advance during the manufacturing of struts and brackets before assembly, providing pre-protection to most surfaces. This preliminary protective action eliminates the need for subsequent complete varnishing, thereby reducing production time while maintaining oxidation resistance.
3Manufacturing precision
If bolted connections are used instead of welding, then welding quality is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates localized unprotected zones on the galvanized surfaces specifically at the connection areas between struts and brackets. This local modification allows welding to be performed directly on bare steel in these zones, achieving proper weld quality while maintaining the galvan化的 protection on all other surfaces, thereby simplifying the connection method compared to bolting.
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 method enables faster, simpler, and more economical production of beams with enhanced oxidation resistance, reducing varnishing times and costs while maintaining the reliability of welded connections, suitable for anti-seismic applications.
Implementation Method 1
The primary protective layer may affect practically the entire external surface and internal surface of the beam except for in a limited welding area... The primary protective layer is a zinc layer which can advantageously be carried out by means of established techniques during the manufacture of the strut and the brackets
Implementation Method 2
The brackets are disposed close to the ends of the strut and can be fixed thereto by means of welding
Implementation Method 3
In the welding area, the external surface of the beam is protected by a secondary protective layer... the secondary protective layer - which has a much more limited extent - can be made readily and rapidly after the strut has been fixed to the brackets
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A beam for shelving units comprises a strut (3) which is elongate in a longitudinal direction and two brackets (5a, 5b) which are provided for attaching the beam (1) to uprights of the shelving unit. The brackets are disposed close to the ends of the strut and fixed thereto by welding. The surface of the beam (1) is protected overall by a primary protection layer which affects almost the entire surface thereof, both internally and externally, and by a secondary protective layer which affects only a limited welding area which surrounds and includes the location at which the ends (3a, 3b) of the strut (3) are close to the respective brackets (5a, 5b).Advantageously, the primary protective layer is made by galvanizing, which is removed in order to expose the welding zone, which is then protected by a layer of varnish as a secondary protective layer.