Storage Rack Crossbeam Integration to Reduce Assembly Complexity
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Solution Overview
Problem
Existing storage rack designs for automatic small parts warehouses face challenges in manufacturing complexity, increased production costs, and reduced load-bearing capacity due to complex crossbeam geometries and the need for additional assembly components like insertion bevels and separate push-through protection devices.
Innovation Solution
The design incorporates longitudinal beams with a permanently angled upper profile flange for easy carton or container placement, slot-shaped openings in the profile web for reduced deflection and increased load-bearing capacity, and U/C-shaped crossbeams with hooking recesses for secure attachment, eliminating the need for separate push-through protection components by integrating them into the beam structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crossbeams are designed with complex geometries including separate insertion bevels and push-through protection devices, then the storage rack achieves functional requirements for carton placement and protection, but the manufacturing complexity and production costs increase significantly
Solution Approach 1:
The patent combines multiple separate components (insertion bevel, push-through protection device, and crossbeam) into a single integrated crossbeam structure. The upper profile flange of the longitudinal beam is formed with an integrated insertion slope, and the rear longitudinal beam includes an integrated push-through protection device, eliminating the need for separate assembly steps and reducing manufacturing complexity while maintaining all required functions.
Solution Approach 2:
The crossbeam is designed to perform multiple functions simultaneously: it provides structural support, facilitates carton insertion through the integrated slope, and prevents over-pushing via the integrated push-through protection device. This multi-functional design reduces the total number of components needed in the storage rack system.
2Stability of the object's composition
If crossbeams rest on longitudinal members with complex connections, then rotationally stable connection is achieved, but the shelf height is reduced due to loss of height between vertically arranged shelves
Solution Approach 1:
The connection between longitudinal beams and crossbeams is segmented into discrete attachment points through slot-shaped openings in the profile web. These openings allow crossbeams to be positioned at specific intervals without requiring continuous contact along the entire length, maintaining stability while minimizing height loss.
Solution Approach 2:
The connection system transitions from a vertical stacking approach to a horizontal integration approach. Slot-shaped openings in the profile web allow crossbeams to attach laterally to longitudinal beams at multiple heights, enabling stable connections without sacrificing vertical shelf height space.
3Reliability
If different components are assembled separately (insertion bevels, push-through protection, crossbeams), then functional requirements are met, but assembly time and production costs increase
Solution Approach 1:
Multiple functional components are merged into single integrated structures: the insertion bevel is formed as part of the longitudinal beam's upper profile flange, and the push-through protection device is integrated into the rear longitudinal beam. This eliminates separate assembly operations for these components, significantly reducing assembly time while maintaining all required functions.
4Ease of operation
If crossbeams have complex geometries with differently designed ends, then specific functions (insertion slope, push-through protection) are achieved, but manufacturing costs increase due to complex manufacturing processes
Solution Approach 1:
The patent merges the insertion slope and push-through protection device into the standard crossbeam and longitudinal beam structures. The upper profile flange of the longitudinal beam is formed with an integrated insertion slope, and the rear longitudinal beam includes an integrated push-through protection device, allowing these specialized functions to be manufactured using the same processes as the main structural components.
Data Source
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AI summary
The rack has longitudinal cross bars (2) fastened at rack supports at a front side and a rear side, and transverse cross bars (6) attached to the longitudinal cross bars, where the transverse cross bars are perpendicular to the longitudinal cross bars. The longitudinal cross bars exhibit C-shaped cross section and have a profile bar (9) with a lower straight partial section (7) and an upper partial section (8) that is bent outwards. An upper profile flange (10) is attached to the bent upper partial section and has a slanted plane (11) that is inclined downwards and outwards.