Wire Deck Open-Channel Beam Assembly to Eliminate Height Differentials
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Solution Overview
Problem
Conventional storage and shelving systems face difficulties due to height differentials caused by overlapping storage decks, leading to increased complexity in transferring items and materials, as well as challenges in installation and assembly.
Innovation Solution
The design incorporates a storage rack assembly with elongated open channels and a deck sheet supported by edge wires and a support member, which minimizes height differentials by allowing the deck to be securely positioned within the channels, facilitating easier installation and improved alignment with the storage rack structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If storage decks are supported on closed cross-sectional beams or rails, then the structure is simple and stable, but height differentials form between adjacent bays making item transfer difficult
Solution Approach 1:
The storage deck is segmented into multiple sections, each supported on its own open channel beam. This segmentation allows each deck section to be independently positioned at the same height, eliminating height differentials between adjacent bays while maintaining structural stability through the modular configuration.
Solution Approach 2:
The beam cross-section is changed from closed (rectangular) to open channel shape. This dimensional change in the beam profile allows the deck to be supported from below through the open channel, enabling precise height alignment between adjacent decks while maintaining structural integrity.
2Ease of manufacture
If conventional closed cross-sectional beams are used, then manufacturing is straightforward, but installation and assembly time increase due to height differential adjustments
Solution Approach 1:
The open channel beams are pre-formed with precise dimensions during manufacturing, ensuring that when assembled, the deck sections automatically align at the correct height without requiring post-installation adjustments. This preliminary precision in beam fabrication eliminates time-consuming height differential corrections during installation.
Solution Approach 2:
Changing the beam cross-section to an open channel profile allows for more precise control of the deck support height during manufacturing. The open channel geometry enables better tolerance control and height precision to be built into the beam itself, reducing installation time.
3Device complexity
If deck sections overlap on common beams, then structural support is simplified, but height differentials increase making the system more complex to operate
Solution Approach 1:
Instead of having deck sections overlap on common beams, the system segments the support structure into separate open channel beams for each deck section. This segmentation allows each deck to be independently positioned at uniform height, eliminating height differentials while maintaining structural simplicity through the modular open channel configuration.
Solution Approach 2:
The transition from closed beam to open channel cross-section enables a different support configuration where decks are positioned side-by-side at the same height rather than overlapping. This dimensional change in the support structure allows uniform deck alignment without increasing operational complexity.
Data Source
AI summary
A storage deck section supportable on a storage rack structure. The storage deck section includes a deck sheet formed from a plurality of wires. At least some of the plurality of wires include a sheet portion at least partially defining an approximately planar support area for supporting associated goods. A relief portion extending from the sheet portion at an acute angle relative to the approximately planar support area. An extension portion disposed along the first end is oriented transverse to the sheet portion. A support member is disposed below the deck sheet, which is secured to a beam with an elongated open channel such that at least part of the relief portion and at least part of the extension portion are disposed within the elongated open channel. A storage rack assembly is also included.