AU2017100201A4 - Method and system for protecting a pallet rack - Google Patents

Abstract

H:\stp\Interwoven\NRPortbl\DCC\STP\13 195445 1.docx-21/02/2017 - 13 A protector system for a pallet rack, the pallet rack having pairs of front and rear upright frames, the pairs of upright frames being interconnected by lateral beams that act to support pallets in use and the protector system including: a base having at least two spaced apart upright supports that are attached to a lower end of a pair of front and rear upright frames to thereby support the pair of upright frames above ground level; and, a bumper defining a perimeter extending around a lower part of the base to thereby at least partially protect the base from impacts and guide insertion or removal of pallets. Fig. 1L -~ 130.2 F 120.1 R10 F-1 100 e 11y20.1 120.2 Fi.1L10120.2 --- 130.2 120.1 - 120.1 Fig. 1M

Description

H:\stp\Interwoven\NRPortbl\DCC\STP\13195445_l.docx-21A)2/2017 2017100201 21 Feb 2017 - 1 - METHOD AND SYSTEM FOR PROTECTING A PALLET RACK Background of the Invention [0001] The present invention relates to a method and system for protecting a pallet rack. Description of the Prior Art [0002] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0003] It is known to store pallets on storage racks, for example, in warehouses, distribution centres, storerooms, and the like. Typically, storage racks include upright frames which are secured to the floor, and which are secured to horizontal storage platforms for supporting pallets of goods. However, the upright columns of such storage racks can be prone to damage affecting the structural integrity of the racks, for example, when positioning and retrieving pallets. Moreover, replacing the upright columns and/or racks can be costly and time consuming.

[0004] US20040155003 describes a storage rack which has upright columns supporting vertically cambered beams having step box or channel shapes accommodating a generally horizontal deck for carrying pallets and product loads. The beams have upward cambers or convex curvatures that increase the load carrying capacity of the rack.

Summary of the Present Invention [0005] In one broad form an aspect of the present invention seeks to provide a protector system for a pallet rack, the pallet rack having pairs of front and rear upright frames, the pairs of upright frames being interconnected by lateral beams that act to support pallets in use and the protector system including: a base having at least two spaced apart upright supports that are attached to a lower end of a pair of front and rear upright frames to thereby support the H:\stp\Interwoven\NRPortbl\DCC\STP\13195445_l.docx-21/0 2/2017 2017100201 21 Feb 2017 -2 - pair of upright frames above ground level; and, a bumper defining a perimeter extending around a lower part of the base to thereby at least partially protect the base from impacts and guide insertion or removal of pallets.

[0006] In one embodiment at least one of: the bumper includes two substantially U-shaped bumper bodies, each body being formed from plate steel shaped to form an end plate having substantially parallel arms extending perpendicularly from the end plate, and wherein arms of the bumper bodies are interconnected to define the perimeter; the base includes two upright supports spaced apart on either side of a central pillar, with upper and lower plates extending between the pillar and upright supports to thereby hold the upright supports in a fixed position, and wherein at least one of the lower plates includes openings adapted to receive a fastener to allow the base to be attached to a floor; and, the base is attached to the upright frames by a sleeve and associated backing plate.

[0007] In one broad form an aspect of the present invention seeks to provide a protector system for a pallet rack, the pallet rack having pairs of front and rear upright frames, the pairs of upright frames being interconnected by lateral beams that act to support pallets in use and the protector system including a bumper defining a perimeter extending around a lower part of a pair of front and rear upright frames to thereby at least partially protect the front and rear upright frames from impacts and guide insertion or removal of pallets.

[0008] In one broad form an aspect of the present invention seeks to provide a method of protecting a pallet rack, the pallet rack having pairs of front and rear upright frames, the pairs of upright frames being interconnected by lateral beams that act to support pallets in use and the method including: attaching a base having at least two spaced apart upright supports to a lower end of a pair of front and rear upright frames to thereby support the pair of upright frames above ground level; and, providing a bumper defining a perimeter extending around a lower part of the base to thereby at least partially protect the base from impacts and guide insertion or removal of pallets.

[0009] In one embodiment the method includes removing a lower part of the front and rear upright frames, the lower part including a damaged portion. H:\stp\Interwoven\NRPortbl\DCC\STP\l 319544 5_l.docx-21/02/2017 2017100201 21 Feb 2017 -3 - [0010] It will be appreciated that the broad forms of the invention and their respective features can be used in conjunction, interchangeably and/or independently, and reference to separate broad forms is not intended to be limiting.

Brief Description of the Drawings [0011] An example of the present invention will now be described with reference to the accompanying drawings, in which: - [0012] Figure 1A is a schematic of a plan view of an example of a bumper of a protector system for a pallet rack; [0013] Figure IB is a schematic of an end view of an example of the bumper of Figure 1A; [0014] Figure 1C is a schematic of a side view of an example of the bumper of Figure 1 A; [0015] Figure ID is a schematic of a plan view of an example of a base of a protector system for a pallet rack; [0016] Figure IE is a schematic of an end view of an example of the base of Figure ID; [0017] Figure IF is a schematic of a side view of an example of the base of Figure ID; [0018] Figure 1G is a schematic of a plan view of an example of the protector system of Figures 1A to IF, in use; [0019] Figure 1H is a schematic of an end view of an example of the protector system of Figure 1G, in use; [0020] Figure II is a schematic of a side view of an example of the protector system of Figures 1A to IF, in use; [0021] Figure 1J is a schematic of an end view of an example of the protector system of Figures 1A to II, in use; [0022] Figure IK is a schematic of an side view of an example of the protector system of Figure 1J, in use; [0023] Figure 1L is a schematic of a perspective view of an example of two protector systems of Figures 1A to IK in use; [0024] Figure 1M is a schematic of a plan view of an example of the protector systems of Figure 1L, in use; H :\stp\Interwoven\NRPortbl\DCC\STP\l 319544 5_ 1 docx-21/02/2017 2017100201 21 Feb 2017 -4- [0025] Figure IN is a schematic of a plan view of an example of the protector system of Figures 1A to IK in use; [0026] Figure 10 is a schematic of a plan view of an example of the protector system of Figures lAto IK, in use; [0027] Figure 2A is a schematic of a plan view of an example of a bumper of a protector system for a pallet rack; [0028] Figure 2B is a schematic of a side view of an example of the bumper of Figure 2A; [0029] Figure 2C is a schematic of a perspective view of an example of a base of a protector system for a pallet rack; [0030] Figure 2D is a schematic of a side view of an example of the base of Figure 2C; [0031] Figure 2E is a schematic of a plan view of an example of a sleeve of a protector system for a pallet rack; [0032] Figure 2F is a schematic of an end view of an example of the sleeve of Figure 2E; [0033] Figure 2G is a schematic of a side view of an example of the sleeve of Figure 2E; [0034] Figure 2H is a schematic of an example of a backing plate of a protector system for a pallet rack; and, [0035] Figure 21 is a schematic of a perspective view of an example of the protector system of Figures 2A to 2H in use.

Detailed Description of the Preferred Embodiments [0036] An example of protector system for a pallet rack will now be described with reference to Figures 1A to 10. In this example, the pallet rack has pairs of front and rear upright frames F, R, the pairs of upright frames I\ R being interconnected by lateral beams that act to support pallets P in use.

[0037] The protector system 100 includes a base 110 having at least two spaced apart upright supports 120.1, 120.2 that are attached to a lower end of the pair of front and rear upright frames F, R to thereby support the pair of upright frames above ground level. In addition, the protector system 100 includes a bumper 150 defining a perimeter extending around a lower part of the base 110 to thereby at least partially protect the base 110 from impacts and guide insertion or removal of pallets. H:\stp\Interwoven\NRPortbI\DCC\STP\l 3195445_l.docx-21/02/2017 2017100201 21 Feb 2017 -5 - [0038] Accordingly, the above mentioned system 100 beneficially protects the pallet rack, thus reducing rack damage which in turn decreases the need to replace rack uprights in their entirety. For example, the protection system can be manufactured from stronger materials than would otherwise be used for the pallet rack upright frames, thereby avoiding damage arising from minor impacts. This reduces the amount of damage arising, whilst avoids the need for an entire frame to be made from a stronger material. As will be appreciated, this provides significant savings in terms of both replacement cost and time.

[0039] Furthermore, as will be described in more detail below, the base can be used to repair a damaged frame, by cutting the frame and removing a lower portion, which is then replaced with the protection system, thereby reducing the cost in repair.

[0040] Moreover, the bumper 150 provides a guide for inserting pallets into the rack, as shown in Figures IN and 10, ensuring the speed of goods storage and retrieval is increased, whilst decreasing the risk of impact between the pallets and the upright frame members or upright supports, which can in turn lead to damage. It will be appreciated from this that the bumper could also be used in conjunction with the pallet rack without the base 110, as will be described in more detail below.

[0041] A number of further features will now be described.

[0042] In one example, the bumper 150 includes two substantially U-shaped bumper bodies, each body being formed from plate steel shaped to form an end plate having substantially parallel arms extending perpendicularly from the end plate, and wherein arms of the bumper bodies are interconnected to define the perimeter. This is particularly advantageous as it allows the bumper to be constructed, for example, from plate steel thus reducing manufacturing costs, as well as ensuring durability and strength. Furthermore, this allows the bumper to be installed in situ, by placing each bumper body around a respective upright frame or upright support and then connecting the two bumper bodies together. As will be appreciated, the bumper bodies may be interconnected in any suitable fashion including fasteners, such as one or more nut/bolt pairs, welding, adhesives, or the like. H:\stp\Interwoven\NRPortbl\DCC\STP\13195445_l.docx-21/02/2017 2017100201 21 Feb 2017 -6- [0043] In one example, a first bumper body includes tabs extending from the end of each of the parallel arms, where tab openings are included in each of the tabs. Accordingly, the second, complementary bumper body includes bumper openings which, in use, when the bodies are interconnected the bumper and tab openings correspond to thereby accept the fasteners such as one or more nut/bolt pairs. However, this is not essential and in another example the first and second bumper bodies may be substantially identical. For example, each bumper body may include a tab including tab openings at the end of one parallel arm, and complementary bumper openings at the end of the opposing parallel arm. Accordingly, the tab openings of one bumper body align with the bumper openings of the other bumper body, and vice versa. It will be appreciated that by using substantially identical bumper bodies which interconnect, manufacturing costs may be reduced.

[0044] In some examples, one or more fasteners are countersunk, for example, countersunk bolts. This is particularly advantageous as it ensures that pallets P and/or other items do catch on the protector system 100, the base 110, the bumper 150, or the like.

[0045] In another example, the base 110 includes two uprights supports 120.1, 120.2 spaced apart on either side of a central pillar, with upper and lower plates 130.2, 130.1 extending between the pillar and upright supports 120.1, 120.2 to thereby hold the upright supports 120.1, 120.2 in a fixed position. Beneficially, this provides the base 110 with additional structural integrity and strength, which in turn provides increased protection for the pallet rack. Construction may be achieved in any suitable manner, including welding, adhering or otherwise fastening the upright supports 120.1, 120.2 and pillar to the upper and lower plates 130.2, 130.2. In some examples, the base 110 may be integrally formed, however this is not essential.

[0046] Optionally, at least one of the lower plates 130.1 includes openings adapted to receive a fastener to allow the base to be attached to a floor. Anchoring the base 110 to the floor minimizes movement of the base 110 when installed, and hence movement of the pallet rack is also obviated, for example, when storing and retrieving pallets P. Advantageously, the openings on the lower plates 130.1 are typically accessible even when the base 110 is installed, thus allowing the fasteners to be easily attached. H:\stp\Interwoven\NRPortbl\DCC\STPU3195445_l.docx-21A)2/2017 2017100201 21 Feb 2017 -7- [0047] Additionally or alternatively, the base 110 is attached to the upright frames F, R by a sleeve and associated backing plate. The sleeve may be provided in order to provide additional support, and/or a means of interconnection, for the base 110 and upright frames F, R. In some examples, the sleeve includes a number of openings, where at least one of the openings corresponds to opening(s) on the upright frames F, R and at least one other opening corresponds to opening(s) on the base 110. Thus, the respective openings are adapted to receive fasteners, such as nut/bolt pairs or the like, in order to interconnect the sleeve with both the frames F, R and base 110.

[0048] Whilst both the bumper 150 and base 110 are shown in Figures 1G to 10, it will be appreciated that in some examples it may be advantageous to utilise the bumper 150 or base 110 exclusively.

[0049] For example, in some instances a protector system 100 for a pallet rack includes a bumper 150 defining a perimeter extending around a lower part of a pair of front and rear upright frames F, R to thereby at least partially protect the front and rear upright frames F, R from impacts and guide insertion or removal of pallets P. In this regard, the pallet rack has pairs of front and rear upright frames F, R, the pairs of upright frames F, R being interconnected by lateral beams that act to support pallets in use.

[0050] Moreover, whilst in some examples the bumper 150 defines the perimeter of a base of the front and rear upright frames F, R, in other examples the bumper 150 may be provided at any height along the upright frames F, R. For instance, the bumper 150 could be supported by the lateral beams in order protect the frames F, R adjacent pallets at various heights above ground level. In this regard, multiple bumpers 150 may be provided around a single pair of upright frames F, R, for example, a bumper 150 in respect of the ground level and each lateral beam interconnected thereto. However, this is not essential, and any suitable number of bumpers 150 may be provided.

[0051] Each of the features herein may be composed of any suitable material, as indicated above. Typically the system 100 is substantially composed of steel, stainless steel, or the like, in order to provide strength and robustness. In some examples, features such as the H:\stp\Interwoven\NRPortbl\DCC\STP\13195445_l.docx-21/0 2/2017 2017100201 21 Feb 2017 - 8 - bumper 150 may additionally incorporate impact-absorbent materials, such as rubber, synthetic rubber, or the like, for additional absorption of impacts during use, however this is not essential.

[0052] A method of protecting a pallet rack will now be described, also with reference to Figures 1A to 10. In this example the pallet rack has pairs of front and rear upright frames F, R, the pairs of upright frames F, R being interconnected by lateral beams that act to support pallets P in use.

[0053] In particular, the method includes attaching a base 110 having at least two spaced apart upright supports 120.1, 120.2 to a lower end of a pair of front and rear upright frames F, R to thereby support the pair of upright frames F, R above ground level. Additionally, the method includes providing a bumper 150 defining a perimeter extending around a lower part of the base 110 to thereby at least partially protect the base 110 from impacts and guide insertion or removal of pallets P.

[0054] Beneficially, this provides additional protection for a pallet rack, for example, from impacts whilst loading or unloading pallets P using a forklift or other suitably heavy duty machinery. Additionally, reducing pallet rack damage ensures that the racks are structurally sound for longer, and decreases the replacement rate, saving both money and time. Moreover, the method may include any one or more of the additional features described herein.

[0055] Whilst typically the base 110 may be attached prior to providing the bumper 150, this is not essential and in other examples the bumper 150 may be provided first. For example, the bumper 150 may be provided, then lifted over the lower part of the upright frames F, R while the base 110 is attached.

[0056] Optionally, the method includes removing a lower part of the front and rear upright frames F, R, where the lower part includes a damaged portion. This is particularly advantageous, as it reduces the need to replace the entire pallet rack, when damaged, thus saving time and money. Moreover, this may be achieved in any suitable manner, for example, by supporting the damaged pallet rack using supports, such as one or more jacks, H:\stp\Interwoven\NRPortbl\DCC\STP\13195445_l.docx-21/0 2/2017 2017100201 21 Feb 2017 -9- cutting the frames F, R in order to removed the damaged portion, replacing the damaged portion with the base 110, and releasing and removing the jack(s). Optionally, the base 110 may be secured to the floor, for example, via openings in a lower plate of the base 110, as discussed above.

[0057] Additionally or alternatively, one or more sleeves and/or associated backing plates may be attached to the base 110 and upright frames F, R, for example as discussed above.

[0058] An example of protector system for a pallet rack will now be described in more detail with reference to Figures 2A to 21.

[0059] In this example, shown in use in Figure 21, the protector system 200 includes a base 210 including two upright supports 220.1, 220.2, spaced apart on either side of a central pillar 220.3. Upper and lower plates (230.2, 230.1) extend between the pillar 220.3 and upright supports 220.1, 220.2 to hold the upright supports 220.1, 220.2 in a fixed position.

[0060] The upright supports 220.1, 220.2 are further attached to a lower end of a pair of front and rear upright frames F, R of the pallet rack, to thereby support the upright frames F, R above ground level. The upright supports 220.1, 220.2 of this example are secured to the ground by bolting through openings 240 in the lower plate 230.1.

[0061] In addition, the system 200 includes a bumper 250 including two substantially U-shaped bumper bodies 251, 252, which are interconnected to define a perimeter extending around a lower part of the base 210 in order to protect the base 210 from impacts and guide insertion or removal of pallets. In this regard, the bumper bodies 251, 252 are interconnected by aligning openings 252.2 in tabs 252.1 extending from the first bumper body 252 with openings 251.1 in the second bumper body 251, and inserting nut/bolts therethrough to secure the interconnection. In this example, the openings 251.1, 252.2 align at a position offset from the pillar 220.3 of the base 210 to thereby allow the bolts to be positioned easily through the openings 251.1, 252.2 after the bumper 250 is installed over the base 210.

[0062] In addition, the system 200 includes two sleeves 260 used to interconnect the front and rear upright frames F, R, and the respective upright supports 220.1, 220.2. In particular, 2017100201 21 Feb 2017 H:\stp\Interwoven\NRPortbl\DCC\STP\13195445_l.docx-21/0 2/2017 - 10-the sleeves 260 include first openings 262 adapted to receive fasteners to allow the sleeves to be attached to the upright frames F, R, and second openings 263 adapted to receive fasteners to allow the sleeves to be attached to the upright supports 220.1, 220.2.

[0063] Furthermore, the system 200 includes an associated backing plate 270, which facilitates attachment of each sleeve 260 to the front and rear upright frames F, R, and respective upright supports 220.1, 220.2. In this regard, the backing plate 270 is substantially planar, and includes a number of openings 272, in this case four, adapted to receive fasteners. It will be appreciated, however, that any number of openings 272 may be included in the backing plate 270. Thus, the backing plate 270 may be fastened to an opposing side of each front and rear upright frame F, R to the respective sleeve 260 such that the openings 272 in the backing plate correspond with the first openings 262 in the sleeve 260 in order to accept the fasteners. Alternatively, the backing plate 270 may be fastened between the sleeve 260 and its respective frame F, R, in order to act as a spacer therebetween.

[0064] Thus, the above advantageously provides a system and method for protecting a pallet rack, which for example allows pallet rack uprights to be partially replaced in the event of damage, saving time and money. Moreover, the system and method decrease the risk of further damage to the pallet rack and/or protector system, ensuring robustness and longevity.

[0065] Throughout this specification and claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers.

[0066] Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.

Claims (5)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1) A protector system for a pallet rack, the pallet rack having pairs of front and rear upright frames, the pairs of upright frames being interconnected by lateral beams that act to support pallets in use and the protector system including: a) a base having at least two spaced apart upright supports that are attached to a lower end of a pair of front and rear upright frames to thereby support the pair of upright frames above ground level; and, b) a bumper defining a perimeter extending around a lower part of the base to thereby at least partially protect the base from impacts and guide insertion or removal of pallets.
2. 2) A system according to claim 1, wherein at least one of: a) the bumper includes two substantially U-shaped bumper bodies, each body being formed from plate steel shaped to form an end plate having substantially parallel arms extending perpendicularly from the end plate, and wherein arms of the bumper bodies are interconnected to define the perimeter; b) the base includes two upright supports spaced apart on either side of a central pillar, with upper and lower plates extending between the pillar and upright supports to thereby hold the upright supports in a fixed position, and wherein at least one of the lower plates includes openings adapted to receive a fastener to allow the base to be attached to a floor; and, c) the base is attached to the upright frames by a sleeve and associated backing plate.
3. 3) A protector system for a pallet rack, the pallet rack having pairs of front and rear upright frames, the pairs of upright frames being interconnected by lateral beams that act to support pallets in use and the protector system including a bumper defining a perimeter extending around a lower part of a pair of front and rear upright frames to thereby at least partially protect the front and rear upright frames from impacts and guide insertion or removal of pallets.
4. 4) A method of protecting a pallet rack, the pallet rack having pairs of front and rear upright frames, the pairs of upright frames being interconnected by lateral beams that act to support pallets in use and the method including: a) attaching a base having at least two spaced apart upright supports to a lower end of a pair of front and rear upright frames to thereby support the pair of upright frames above ground level; and, b) providing a bumper defining a perimeter extending around a lower part of the base to thereby at least partially protect the base from impacts and guide insertion or removal of pallets.
5. 5) A method according to claim 4, wherein the method includes removing a lower part of the front and rear upright frames, the lower part including a damaged portion.