AU2016225930A1 - Device and Method for Accessing a Racking System - Google Patents

Abstract

The present invention relates to the field of storage racking, particularly pallet racking of the type used in storage facilities. Aspects of the present invention relate to an access cradle or work platform, as well as a method of assembly of a racking system. 33 kl

Description

The present invention relates to the field of storage racking, particularly pallet racking of the type used in storage facilities. Aspects of the present invention relate to an access cradle or work platform, as well as a method of assembly of a racking system.

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AUSTRALIA

Patents Act 1990

P/00/011

Regulation 3.2(2)

ORIGINAL

COMPLETE SPECIFICATION

STANDARD PATENT

Application No.

Lodged:

Invention Title: Device and Method for Accessing a Racking System

The following statement is a full description of this invention, including the best method of performing it known to:

2016225930 09 Sep 2016

DEVICE AND METHOD FOR ACCESSING A RACKING SYSTEM

FIELD OF INVENTION [0001] The present invention relates to the field of storage racking, particularly pallet racking of the type used in storage facilities.

[0002] It will be convenient to hereinafter describe the invention in relation to pallet racking for warehouses, however it should be appreciated that the present invention is not limited to that use only and can be used for other types of racks for storing goods in a range of locations.

BACKGROUND ART [0003] It is to be appreciated that any discussion of documents, devices, acts or knowledge in this specification is included to explain the context of the present invention. Further, the discussion throughout this specification comes about due to the realisation of the inventor and/or the identification of certain related art problems by the inventor. Moreover, any discussion of material such as documents, devices, acts or knowledge in this specification is included to explain the context of the invention in terms of the inventor’s knowledge and experience and, accordingly, any such discussion should not be taken as an admission that any of the material forms part of the prior art base or the common general knowledge in the relevant art in Australia, or elsewhere, on or before the priority date of the disclosure and claims herein.

[0004] Large retail entities such as general stores and or supermarkets typically store substantial quantities of goods at a central warehouse. The goods are then distributed to branch warehouses or retail stores. The goods inventory and volume can be enormous.

[0005] It is a basic logistic and economic necessity that the warehouse hold as much as possible. It is also a basic necessity that the goods have to be arranged as fast as possible and retrieved as fast as possible when an order is received. To cope with the logistic demands, order picking systems such as those described in US patent 8,827,619

2016225930 09 Sep 2016 and PCT/EP2007/0045536 have been developed for order picking goods stored in rack warehouses.

[0006] There are many varieties of racking for the storage of goods in horizontal rows with multiple levels, often extending over 50 metres in height.

[0007] The racks typically comprise a frame. Most racks comprise rectangular frames defined by horizontal members and vertical members and are optionally strengthened by diagonal and horizontal braces. Three or more frames may be combined to form a module. During assembly, modules are lifted into place by a crane using self releasing crane hooks.

[0008] Metal, timber or wire mesh decking provides a flat surface for supporting the goods and pallet supports comprising roll formed channels on the load beams may be used for supporting pallets. The racks frames are often secured by footplates bolted to the warehouse floor and wall ties connected to the warehouse walls.

[0009] Depending on the configuration of the racks, the goods may be arranged on the racks and retrieved by a number of different systems. Drive-in systems utilise a forklift to put goods directly onto racks. Other systems use forklifts to place or remove goods on wheeled carts running on rails located on the rack frame. Another system uses a heavy duty rolling carriages on the rack to automatically mobilise pallets of goods.

[0010] Very narrow aisle (VNA) racking uses racks in a tighter configuration to provide maximum space utilization within a warehouse. This configuration is often used in conjunction with wire-guided or rail-guided reach-truck system for arrangement of goods. Advantages of VNA racking include improved use of space and concomitant increase in speed of picking.

[0011] Assembly of racking is typically carried out using cranes to lift frame modules into position. Installation and securing of each frame module is carried out manually with scissor lifts or small mobile cranes (cherry pickers) being used to transport and elevate workers to appropriate access points where they can bolt together structural members to form the rack. When VNA racking systems are used, there are limitations on the

2016225930 09 Sep 2016 physical size of the scissor lift or crane that can be used and concomitantly the maximum working height is no more than about 10 metres. Accordingly, a problem arises if the desired racking height exceeds the range of elevation.

[0012] In some instances workers are required to climb the racking as it is assembled to elevated heights. Working at height raises obvious safety risks. Safety harnesses and fall protection are usually required by occupational health and safety laws, limiting worker mobility and increasing the time and cost of rack assembly.

[0013] Accordingly there is a need for an improved method of assembling racking systems, particularly racking systems having substantial height.

SUMMARY OF INVENTION [0014] An object of the present invention is to provide an improved method for accessing racking systems.

[0015] Another object of the present invention is to provide an improved method for assembling racking systems in large storage facilities.

[0016] Another object of the present invention is to provide an improved method for accessing goods stored on racking systems.

[0017] A further object of the present invention is to alleviate at least one disadvantage associated with the related art.

[0018] It is an object of the embodiments described herein to overcome or alleviate at least one of the above noted drawbacks of related art systems or to at least provide a useful alternative to related art systems.

[0019] In a first aspect of embodiments described herein there is provided an access cradle comprising:

2016225930 09 Sep 2016 • a primary platform adapted to support a user in an elevated position adjacent a racking system, and • at least one secondary platform extendable from the primary platform, wherein extension of the at least one secondary platform increases user access to the racking system.

[0020] In another aspect of embodiments described herein there is provided a method of accessing a racking system using an access cradle according to the present invention, the method including the steps of:

• locating a primary platform of the access cradle in an elevated position adjacent a first part of the racking system, • extending a secondary platform from the primary platform, • using the secondary platform to access the first part of the racking system.

[0021] A method of assembling a racking system comprising multiple structural members, the method using an access cradle according to claim 1 and including the steps of:

• locating the primary platform of the access cradle in an elevated position adjacent a first part of the racking system, extending a secondary platform from the primary platform, • using the secondary platform to access the first part of the racking system, • attaching one or more structural members to the first part of the racking system.

2016225930 09 Sep 2016 [0022] Access to the racking system may be required for a variety of activities. These include adding, removing or re-arranging goods stored on the racking system or attaching one or more racking members to build or extend the racking system.

[0023] Where used herein the term ‘access cradle’ is intended to refer to a temporary or movable structure permitting workers to stand or sit at an elevated position above ground or floor level.

[0024] Typically the primary platform of the access cradle is rectangular in shape and has a metal sheet or metal mesh floor.

[0025] In use, optimally the primary platform can be located approximately level and flush with the flat surfaces of the racking on which pallets are supported. Furthermore, it is preferable that during construction of the racking the primary platform can be located adjacent the areas that workers need to access, such as areas where racking frame modules need to be secured together, or areas where services, such as fire sprinklers or electrical wiring need to be installed or maintained.

[0026] At least part of the perimeter of the primary platform includes fall protection such as posts and rails, walls or other suitable structures. In a particularly preferred embodiment the fall protection comprises two or more units, which can be moved to different positions along the perimeter of the primary platform and/or the one or more secondary platforms. For example, the units may be sliding panels which can be moved to provide access between the primary platform and an extended secondary platform, or to change the position of fall protection provided at the perimeter of the primary or secondary platforms.

[0027] The secondary platform is also typically rectangular in shape and has a flat metal sheet or mesh floor. The secondary platform may extend in any convenient direction from the primary platform, but typically the longitudinal axes of the primary and extended secondary platforms are perpendicular. Preferably, when retracted, the secondary platforms fit within the primary platform. The primary and secondary platforms may thus be in a telescopic arrangement.

2016225930 09 Sep 2016 [0028] In a particularly preferred embodiment a secondary platform can be extended from a first side of the primary platform, then retracted and subsequently extended from a second side of the primary platform.

[0029] The secondary platform may extend or retract from the primary platform by any convenient motorised means or manual means. The secondary platform may include a bearing that provides free motion in one direction, or multiple directions. In a preferred embodiment a motorised linear slide is used, such as a machine slide, XY table, roller table or dovetail slide mechanism. Alternatively the slide may comprise ball bearing or roller slides for manual movement. The bearings may be, for example, ball bearings, dovetail bearings, linear roller bearings, magnetic or fluid bearings. In one embodiment the secondary platform is extended and retracted by movement along rails, guides or slides.

[0030] In a particularly preferred embodiment the secondary platform extends or retracts from the primary platform by virtue of wheels associated with one platform rolling along a C-section associated with the other platform. Surfaces of the primary and secondary platforms that are in sliding contact may be coated or lined with Teflon™ or another material that reduces friction between the surfaces.

[0031] In a further preferred embodiment one or more secondary platforms have further extension capabilities. For example the aforementioned fall protection such as posts and rails, walls or other structures may be able to be extended from the secondary platform. In a particularly preferred embodiment the secondary platforms have walls that can be extended from the secondary platform.

[0032] In another embodiment, the access cradle according to the present invention includes at third, and optionally subsequent platforms which are arranged in a telescopic fashion.

[0033] In another preferred embodiment, the access cradle according to the present invention includes a section that is detachable and can be lowered and raised from the first platform by a hoist or other similar device built into the access cradle. This allows

2016225930 09 Sep 2016 workers to be conveniently lowered down through the frame modules to desired locations.

[0034] The access cradle can be moved between elevated positions adjacent the racking system by any conveniently adjustable suspension means. For example, it may be supported at a single point or multiple points by an overhead gantry, power traction hoist, winding drum hoist, crane or a lifting devices which is attached to the racking or warehouse structural elements such as a roofing member.

[0035] Preferably the access cradle includes a means for providing support or stability and maintaining the primary platform adjacent the racking system. For example, the means may comprise one or more releasable hooks which can be hooked over members of the racking system when the platform is in use, and released when the access cradle is being moved between elevated positions. Preferably the hooks can be swivelled into and out of preferred positions.

[0036] Other aspects and preferred forms are disclosed in the specification and/or defined in the appended claims, forming a part of the description of the invention.

[0037] In essence, embodiments of the present invention stem from the realization that a work platform can be modified to have a primary platform include an additional extendable secondary platform, extendable away from the primary platform, and extendable in a direction required to enable work to be performed, without the need to have a workman independently suspended from the work platform.

[0038] Advantages provided by the present invention comprise the following:

• improved occupational health and safety for workers working with goods stored in racking systems or assembling racking systems, improved access to elevated racks in large storage facilities, • facilitates assembly of relatively high racking systems, and • can be ustilised in situations where scissor lifts or cranes cannot be used.

2016225930 09 Sep 2016 [0039] Further scope of applicability of embodiments of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure herein will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS [0040] Further disclosure, objects, advantages and aspects of preferred and other embodiments of the present application may be better understood by those skilled in the relevant art by reference to the following description of embodiments taken in conjunction with the accompanying drawings, which are given by way of illustration only, and thus are not limitative of the disclosure herein, and in which:

FIG. 1 illustrates a access cradle according to the present invention with three secondary platforms extending from the primary platform;

FIG. 2 illustrates another embodiment of the access cradle of the present invention in an elevated position within a racking system with secondary and tertiary platforms extending telescopically from the primary platform;;

FIG. 3 illustrates the access cradle of FIG. 1 with three secondary platforms extending from the primary platform, one of the secondary decks having further extension capabilities;

FIG. 4 illustrates a further embodiment of the access cradle according to the present invention having a section that is detachable and can be lowered by a hoist or other similar device;

FIG. 5 illustrates assembly of modular frames to form racking using the access cradle of the present invention (side view);

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FIG. 6 illustrates the assembly of modular frames of FIG. 5 (front view) showing detachable platform in use; and

FIG. 7 illustrates the assembly of FIG. 6 with further modules.

DETAILED DESCRIPTION [0041] FIG. 1 illustrates an access cradle according to the present invention having a rectangular shaped primary platform (1) having a perimeter defined by four sides. Three secondary platforms (3,5,7) extend from one side of the primary platform, the longitudinal axes of the primary and secondary platforms being perpendicular. In this embodiment the secondary platforms (3,5,7) all extend from the same side of the primary platform (1) however it will be readily appreciated that in alternative embodiments one or more secondary platforms could extend from any one or more of the sides of the primary platform.

[0042] Most of the perimeter of the primary platform (1) includes a wall that acts as fall protection for a user. In this embodiment the wall extends around the perimeters of each of the secondary platforms (3,5,7) so that the users are effectively boxed in. In this embodiment the wall comprises multiple panels that can be re-arranged in accordance with the secondary platforms (3,5,7) being retracted into the primary platform (1) or extended from one side or the other of the primary platform (1).

[0043] In this embodiment the access cradle includes four hooks (11,13,15,19). These hooks (11,13,15,19) can be used as attachment points for cables auto-hooked to a crane. By this means the access cradle can be lifted and shifted between desired position relative to the racking frame modules.

[0044] Preferably the four hooks (11,13,15,19) are able to swivel and can be releasably hooked over members of a racking system when the platform is in use and released when the access cradle is being moved as depicted in FIG. 2. In a preferred embodiment of the platform depicted in FIG. 1 all three secondary platforms can be further extended. Specifically, a portion (25) of the wall extending around the periphery of the access cradle can be slidably extended beyond the end of the secondary deck (3).

2016225930 09 Sep 2016

This extension capability may be useful for specialised access, such as for fire services tasks, such as sprinkler installation.

[0045] This is illustrated in the embodiment illustrated in FIG. 2 which shows the access cradle in an elevated position in a racking system, with two of the hooks (11,13) in engagement with a horizontal member (21) of the racking system, and the other two hooks (15,19) in engagement with another horizontal member (23). The hooks provide support or stability and maintain the primary platform adjacent the racking system. A secondary platform (3) and a tertiary platform (4) extend telescopically from the primary platform (1) and can be retracted to entirely fit within the primary platform (1).

[0046] FIG. 3 illustrates the access cradle of FIG. 1 with three secondary platforms (3,5,7) extending from the primary platform (1).

[0047] FIG. 4 illustrates a further embodiment of the access cradle according to the present invention having an end section that is detachable and can be lowered by a hoist or other similar device built into the access cradle. In particular, the detachable end section includes four hooks (30,31,33,35) and is partially enclosed by walls (25,27). This allows workers to be conveniently lowered down through the frame modules to desired locations.

Racking Assembly [0048] Assembly of the racking will be described with reference to FIG. 5 and FIG. 6. Typically, during assembly of racking, a first module (51) is lifted into place by a crane (70) using self releasing crane (auto) hooks and secured by footplates bolted to the warehouse floor. A second module (52) is lifted into position adjacent the first module and similarly bolted to the warehouse floor.

[0049] The crane then lifts the access cradle (60) and workers and lowers them into position adjacent the first and second modules. The workers can secure the access cradle (60) onto the frame members using the releasable hooks, and release the crane hook from the crane cable (62). The access cradle (60) is then fully supported on the first frame module (51) and second frame module (52), adjacent the location where a

2016225930 09 Sep 2016 third module (53) will be secured to the second module (52). The crane (70) then lifts the third module (53) into position adjacent the second module (52).

[0050] In a particularly preferred embodiment the secondary platform (3) can be extended from a first side of the first platform (1), allowing improved access to the securing points between the second module (52) and third module (53). Once the third module (53) is secured, the crane auto-hooks can be released to free the cable (62). The crane is then free to lift and locate a fourth module (54).

[0051] The crane lifts the fourth module (54) into position adjacent the first module (51). In a particularly preferred embodiment the secondary platform of the access cradle (60) can be extended from a second side of the first platform, allowing improved access to the securing points between the first module (51) and fourth module (54). Once the fourth module (54) is secured, the crane auto-hooks can be released to free the crane cable (62).

[0052] The crane can then continue lifting modules (55,56,57,58) into place and when necessary, lifting the access cradle (60) into positions where workers can releasably hook it to the frame and secure modules together. In particular, FIG. 5 shows all the modules (51 -58) in place to form the racking, with the access cradle (60) according to the present invention having been lifted into position and hooked between the seventh module (57) and eighth module (58) at the top of the racking.

[0053] FIG. 6 provides a side view of the racking depicted in FIG. 5. This view also illustrates how one end section (64) of the access cradle (60) has been lowered through the racking to a position where the workers onboard are in a position to bolt together frame members for a second row of modules, shown still attached to the crane cable (62). FIG. 7 illustrates the assembly of FIG. 6 with further modules.

[0054] This procedure may be carried out using as many access cradles (60,66) as required to complete the construction of the racking.

[0055] For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “interior,” “exterior,” and derivatives thereof shall

2016225930 09 Sep 2016 relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawing, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. Additionally, unless otherwise specified, it is to be understood that discussion of a particular feature of component extending in or along a given direction or the like does not mean that the feature or component follows a straight line or axis in such a direction or that it only extends in such direction or on such a plane without other directional components or deviations, unless otherwise specified.

[0056] While this invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification(s). This application is intended to cover any variations uses or adaptations of the invention following in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth.

[0057] As the present invention may be embodied in several forms without departing from the spirit of the essential characteristics of the invention, it should be understood that the above described embodiments are not to limit the present invention unless otherwise specified, but rather should be construed broadly within the spirit and scope of the invention as defined in the appended claims. The described embodiments are to be considered in all respects as illustrative only and not restrictive.

[0058] Various modifications and equivalent arrangements are intended to be included within the spirit and scope of the invention and appended claims. Therefore, the specific embodiments are to be understood to be illustrative of the many ways in which the principles of the present invention may be practiced. In the following claims, means-plus-function clauses are intended to cover structures as performing the defined function and not only structural equivalents, but also equivalent structures.

2016225930 09 Sep 2016 [0059] “Comprises/comprising” and “includes/including” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. Thus, unless the context clearly requires otherwise, throughout the description and the claims, the words ‘comprise’, ‘comprising’, ‘includes’, ‘including’ and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

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Claims (6)

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FIG. 1 ο

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1. An access cradle comprising:

• a primary platform adapted to support a user in an elevated position adjacent a racking system, and • at least one secondary platform reversibly extendable from the primary platform, wherein extension of the at least one secondary platform increases user access to the racking system.

2. An access cradle according to claim 1 wherein the secondary platform includes extendable fall protection.

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FIG. 3

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3. An access cradle according to claim 1 further including a detachable section that can be lowered and raised from the first platform.

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FIG. 4

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4. A method of assembling a racking system according to claim 3 wherein the first part of the racking system is a first racking frame module and the one or more structural members for attachment comprise second and subsequent racking frame modules.

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4. A method of accessing a racking system using an access cradle according to claim 1, the method including the steps of:

• locating the primary platform of the access cradle in an elevated position adjacent a first part of the racking system, • extending a secondary platform from the primary platform, • using the secondary platform to access the first part of the racking system.

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FIG. 5

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5. A method of assembling a racking system comprising multiple structural members, the method using an access cradle according to claim 1 and including the steps of:

2016225930 09 Sep 2016 • locating the primary platform of the access cradle in an elevated position adjacent a first part of the racking system, • extending a secondary platform from the primary platform, • using the secondary platform to access the first part of the racking system, • attaching one or more structural members to the first part of the racking system.

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FIG. 6

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FIG. 7