Abstract: A structure and method for safely loading and unloading pallet carts to and from multi-level commercial storage racks includes a security structure to catch the carts, in case they fall during the loading or unloading procedure. A pair of rail structures typically extends from the front to the rear of a storage bay. Pallet transportation carts travel on a lower surface of these rail structures and the pallets rest on an upper surface of the rails. A cart security structure in the form of a grate is positioned under the rails, at least at the front of the storage bay. The cart security structure should be about as wide as the space between the rails and should be sufficiently below the rails, so as not to interfere with cart movement. The structure should be constructed to prevent the accumulation of items that can interfere with pallet loading.

Abstract: A system and method for operating robotic pallet transportation carts and providing uniform spacing between pallets of goods, to improve the vertical alignment of the gaps between the pallets of a multilevel commercial warehouse rack. Indicators are positioned along a storage lane, such as on side walls of cart support rail structures, on the left and/or right sides with respect to the pallet transportation cart. The cart has one or more sensors (optical, magnetic and otherwise), such as on a side of the cart to detect the indicators on the side of the lane. The cart is programmed to count the indicators and lower the pallet of goods after sensing a selected indicator number. By spacing the indicators an appropriate distance apart, the pallets can be arranged to have vertically aligned gaps, even if there are minor variations in the length of pallets of goods.

Abstract: An alignment tool and method that is easy to use during the installation of a base of a commercial storage rack over bolts extending up from a warehouse floor. The alignment tool comprises a cylindrical body having a first conically shaped upper end and a second lower end having a bolt receiving hollow opening therein. The opening extends up into said cylindrical body along a longitudinal axis of the body. The method includes placing the opening down over the bolts, with the conical top facing up, to protect the bolts and align the base as it is lowered over the bolts. The alignment tool can be easily removed, prior to bolting the base to the floor, such as with a removal tool through a hole in the alignment tool.

Abstract: A storage system and method wherein a storage rack has a first flat section, where pallets are loaded onto storage rails by an automated pallet transportation cart, and a second inclined flow section, where pallets are moved to the front of the storage lane by the force of gravity. A transition section can be positioned between the flat section and the inclined section. The transition section has rails and spacing for a pallet cart to load pallets onto the inclined section. As the front pallet is removed, the second pallet (and subsequent pallets on the inclined section) travels forward to take its place under the force of gravity. Therefore, no pallet cart is needed to unload the inclined section.

Abstract: Warehouse support structures capable of supporting heavy loads are supported by support members coupled to horizontal support beams, attached to vertical columns. The structure can comprise wire a mesh platform. The front end can be bent down, to nest against a horizontal support beam. The rear end can be bent up, over the horizontal to act as a pallet safety stop. It can also extend rearwards from the horizontal beam to provide additional support surface area. The construction presents a smooth, easy to assemble, snag free construction.

Abstract: A system and method for operating robotic pallet transportation carts and providing uniform spacing between pallets of goods, to improve the vertical alignment of the gaps between the pallets of a multilevel commercial warehouse rack. Indicators are positioned along a storage lane, such as on side walls of cart support rail structures, on the left and/or right sides with respect to the pallet transportation cart. The cart has one or more sensors (optical, magnetic and otherwise), such as on a side of the cart to detect the indicators on the side of the lane. The cart is programmed to count the indicators and lower the pallet of goods after sensing a selected indicator number. By spacing the indicators an appropriate distance apart, the pallets can be arranged to have vertically aligned gaps, even if there are minor variations in the length of pallets of goods.

Abstract: A C-beam constructed to satisfy RMI and MHI standards for supporting two 2500 lb pallets over a 96 inch span and exhibit acceptable deflection, within industry safety specifications, that previously had only been satisfied by 4 inch C-beams of over 4 lb/ft, by optimizing the web thickness and the upper and lower flange dimensions. The beam is constructed, adapted, configured and dimensioned, such that it can weigh less than about 3.7 lb/ft, even less than about 3.55 lb/ft, and when supported at each end, will support an evenly distributed load of over 2400 lb, even 2500 lb, with a deflection of less than about 1/180 of its length.

Abstract: A cart for supporting pallets weighing over 2000 lbs and even over 3000 pounds and transporting those pallets on rails is provided. The carts are formed by releasably attaching a minimal number of pieces, such as by bolting the parts together. By making the parts substantially identical and making the parts as symmetric mirror images, a single part can have multiple uses, such as on both the left and right sides or both the front and back. For example, a rear cross beam can have the same dimensions as a middle cross beam and/or a front cross beam. A left side beam can be identical to a right side beam. A right side bracket for connecting beams and/or mounting wheels can be identical to a left side bracket and a front bracket can be identical to a rear bracket.

Abstract: A horizontal support beam is provided with a vertical connection bracket, constructed to attach the horizontal beam to a vertical column of a storage rack system. The vertical connection bracket includes a plurality of protrusions positioned to eliminate some of the gaps that can exist between the bracket and column. The vertical connection bracket can be an L shaped angle bracket. An inside surface of the first arm can include a plurality of protrusions, which can be formed by pressing dimples into the first arm, to help ensure a tight, contacting fit between the inside surface of the first arm and the vertical column.

Abstract: Warehouse support structures capable of supporting heavy loads are supported by support members coupled to horizontal support beams, attached to vertical columns. The structure can comprise wire a mesh platform. The front end can be bent down, to nest against a horizontal support beam. The rear end can be bent up, over the horizontal to act as a pallet safety stop. It can also extend rearwards from the horizontal beam to provide additional support surface area. The construction presents a smooth, easy to assemble, snag free construction.

Abstract: A C-beam constructed to satisfy RMI and MHI standards for supporting two 2500 lb pallets over a 96 inch span and exhibit acceptable deflection, within industry safety specifications, that previously had only been satisfied by 4 inch C-beams of over 4 lb/ft, by optimizing the web thickness and the upper and lower flange dimensions. The beam is constructed, adapted, configured and dimensioned, such that it can weigh less than about 3.7 lb/ft, even less than about 3.55 lb/ft, and when supported at each end, will support an evenly distributed load of over 2400 lb, even 2500 lb, with a deflection of less than about 1/180 of its length.

Abstract: Warehouse support structures capable of supporting 3000 pounds or more are fastened to the inside surface of a horizontal support beam attached to a vertical column. A structural support member spans the horizontal support beams and support a platform, such as a mesh platform is supported thereon. The support member can be an inverted formed U or an angle beam. The angle beam should have an attachment bracket secured to each end, at a height to permit the platform to have the same height as the horizontal beam. The mesh platform should nest in the inside surface of the horizontal beam, between the support member and the beam. The construction presents a smooth, easy to assemble, snag free construction.

Abstract: A storage system having e.g., side-by-side dual pallet bays is provided. The system includes a single level or stacked multilevel storage bay. Each bay is defined by a series of vertically extending supports and a central divider for storing two rows of pallets. Preferably, there are no vertical supports extending up from the central divider. Rails are provided on both sides of each row for supporting pallets and for pallet transportation/inventory carts to travel under the pallets. Side and center guides having camming surfaces are provided to properly position the pallets in the bays as they are loaded from a forklift.

Abstract: An apparatus is disclosed that provides a storage system designed to allow pickers to easily and efficiently pull products from all portions of the storage system from a single side of the storage system. The storage system includes a first storage rack that has a first plurality of columns and a first platform extending from one of the first plurality of columns. An outer edge of the first platform forms an end of the first storage rack. Positioned adjacent to the first storage rack is a second storage rack with a second plurality of columns and a second platform that extends from one of the second plurality of columns, where an outer edge of the second platform forms an end of the second storage rack. An aisle is formed by a predetermined distance between the outer edges of the first and second platforms.

Abstract: An alignment tool that is easy to use during the installation and fastening of storage rack is disclosed herein. The alignment tool comprises a first end having a conical shape and a second end defining an opening therein, and the opening extending into said cylindrical body along the longitudinal axis. Once the storage rack is installed, the alignment tool can be easily removed with a removal tool through a hole in the alignment tool.

Abstract: A pallet storage system and method are provided. A rack for storing pallets loaded with goods is constructed with a corresponding pair of left and right rails. Carts for supporting the pallets ride on those rails. The rails can have an I-beam shape cross section, include a lower horizontal wall, a vertical wall extending up from the lower horizontal wall and an upper horizontal wall at the top of the vertical wall. The lower and upper horizontal walls include an outer flange extending from the vertical wall in a sideways direction away from the corresponding other rail and an inner flange, extending sideways towards the corresponding other rail. The carts can nest, until loaded and the front of the carts can be flush at the front of the rack.

Abstract: A horizontal support beam is provided with a vertical connection bracket, constructed to attach the horizontal beam to a vertical column of a storage rack system. The vertical connection bracket includes a plurality of protrusions positioned to eliminate some of the gaps that can exist between the bracket and column. The vertical connection bracket can be an L shaped angle bracket. An inside surface of the first arm can include a plurality of protrusions, which can be formed by pressing dimples into the first arm, to help ensure a tight, contacting fit between the inside surface of the first arm and the vertical column.

Abstract: A lane divider system includes a guide rail and a bracket for connecting the guide rail to a flow bed. The guide rail can be tubular, with a proximal end of a bracket inserted into each end of the tube. A flexible, compressible sleeve can be installed at each end of the tube where the proximal end of the bracket, are inserted into the tube. The tube and bracket being inserted should be closely dimensioned to fit securely. By providing a compliant sleeve, the security of the connection with the tube can be enhanced.

Abstract: A lane divider system includes a guide rail and a lane divider bracket for connecting the guide rail to the loading and unloading ends of a flow bed. The guide rail can be tubular, with a proximal end of the bracket inserted into each end of the tube. Retention devices for releasably securing the distal ends of brackets to the loading and unloading ends of the flow bed can include a pin, inserted through an opening in the distal end of the bracket, beneath where the bracket is inserted through the flow bed. Preferred pins can include a handle portion for inserting and pulling the pin out of the opening in the locking structure, such as a split cotter pin, resilient projection, spring clip and the like, to resist the unintentional withdrawal of the pin from the end of the lane divider.

Abstract: A pallet cart including a mechanism to help secure the cart to a forklift. The cart can move through a warehouse with racks of goods and receive signals and store information about the inventory on the racks. The unit can be moved to another location with a forklift. The security mechanism can comprise one or more magnets, retractable structures or other structures to secure the cart to the steel fork of a forklift during transport.