Abstract:
A safety device for a storage rack can include a length of webbing configured to span across a rear side of the storage rack. A sensor device can be coupled to one end of the webbing and a signaling device can be configured to communicate with the sensor device. The signaling device can include a selectively actuatable alert indicator. The sensor device can be operable to sense an increase in tension in the webbing when an item is placed in a position on the storage rack so as to engage the webbing. The sensor device can generate a signal indicative of the increase in tension and communicate the signal to the signaling device. The signaling device can be operable to actuate the at least one alert indicator responsive to the communicated signal so as to provide an indication of a position of the item relative to the storage rack.

Description:
FIELD 
     The present disclosure relates generally to a safety and positioning device for a storage rack. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Storage racks are commonly used in manufacturing facilities and other operations where palletized goods are required to be stacked and stored. A forklift is typically used to place the palletized goods in the storage racks. These storage racks can often include multiple levels stacked vertically such that several of the stacked levels are above a line of sight of the forklift driver. In such a scenario, it can be difficult for the forklift driver to ascertain proper positioning of the palletized goods on the storage rack. 
     Additionally, the palletized goods can often be of a size so as to prevent the forklift operator from being able to effectively see behind or around the palletized goods when placing the goods on the storage rack. Under such a circumstance, it can also be difficult to effectively position the palletized goods on the storage rack, even at one of the lower levels. 
     Thus, while storage rack arrangements have generally worked for their intended purpose, there remains a need for continuous improvement in the relevant art. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     According to one aspect, the present teachings provide a safety device for a storage rack. A length of webbing can be configured to span across a rear side of the storage rack that is adapted to store an item. A sensor device can be coupled to one end of the webbing and a signaling device can be configured to communicate with the sensor device. The signaling device can include at least one selectively actuatable alert indicator. The sensor device can be operable to sense an increase in tension in the webbing when the item is placed in a position on the storage rack so as to engage the webbing. The sensor device can be further operable to generate a signal indicative of the increase in tension and communicate the signal to the signaling device. The signaling device can be operable to actuate the at least one alert indicator responsive to the communicated signal to provide an indication of a position of the item relative to the storage rack. 
     According to another aspect, the present teachings provide a storage structure assembly having a storage rack and a safety device. The storage rack can include a base configured to receive an item where the base includes a front side opposite a rear side, and first and second sides spaced apart from each other and connecting the respective front and rear sides. A first pair of legs can be coupled to the base proximate the rear side and a second pair of legs can be coupled to the base proximate the front side. The safety device can include first and second brackets adjustably coupled to the respective first pair of legs, a length of webbing configured to span across the rear side of the storage rack, and a sensor device coupled to one of the first and second brackets. The webbing can be coupled at one end to the sensor device and at another end to the other of the first and second brackets. A signaling device can be configured to communicate with the sensor device and can include at least one selectively actuatable alert indicator. The sensor device can be operable to sense movement or a change in tension in the webbing when the item is placed in a position on the base of the storage rack so as to engage the webbing. The sensor device can be further operable to generate a signal indicative of the movement or change in tension and communicate the signal to the signaling device. The signaling device can be operable to actuate the at least one alert indicator responsive to the communicated signal to provide an indication of a position of the item relative to the storage rack. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The present teachings will become more fully understood from the detailed description, the appended claims and the following drawings. The drawings are for illustrative purposes only and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a perspective view of an exemplary storage rack having a safety and positioning device in accordance with the teachings of the present disclosure. 
         FIG. 2  is a perspective view of an exemplary storage rack having an alternative safety and positioning device in accordance with the teachings of the present disclosure. 
         FIG. 3  is a top view of an item interacting with the safety and positioning device of  FIG. 1  or  2  in accordance with the teachings of the present disclosure. 
         FIG. 4  is a side view of an exemplary storage rack having multiple levels with each level including at least one safety and positioning device in accordance with the teachings of the present disclosure. 
         FIG. 5  is a partial schematic view of an exemplary tension sensing device in accordance with the teachings of the present disclosure. 
         FIG. 6  is a partial schematic view of an exemplary movement sensing device in accordance with the teachings of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
     With initial reference to  FIGS. 1 and 4 , a safety and positioning device  10  is shown operatively associated with a storage rack  12 . The storage rack  12  may be any conventional storage rack suitable for receiving boxes, packages or other items  13  on a pallet  14  that is positioned on the rack  12  by a forklift  16  or other suitable device. The storage rack  12  may include a floor or base  18  having a generally rectangular shape  20 . Base  18  may include various shapes depending on, for example, space available for rack  12  and the size of pallets  14  that may be placed on base  18 . Base  18  may include a front side  22 , a rear or back side  24  and lateral sides  26 ,  28  connecting the front and back sides  22 ,  24 , respectively. Support legs  30 ,  32  may be coupled to sides  26 ,  28  adjacent to back side  24 , and support legs  34 ,  36  may be coupled to sides  26 ,  28  adjacent to front side  22 , as shown in  FIG. 1 . The legs  30 - 36  may include a C-channel configuration  38  for added strength or other configurations suitable for providing additional strength while also serving to reduce an amount of material required to provide the added strength. 
     The storage rack  12  may include multiple levels having multiple bases  18  spaced apart from each other such that each base  18  can receive pallets  14  containing a package or packages  13 , as shown in  FIG. 4 . The base  18  can also be permanently secured to legs  30 - 36  or can be adjustably secured to legs  30 - 36  such that a position of base  18  can be varied relative to the legs and/or another base  18 . 
     With continued reference to  FIG. 1  and additional reference to  FIGS. 2-3  and  5 - 6 , the safety and positioning device  10  will now be described. The safety and positioning device  10  may include first and second bracket assemblies  50 ,  52 , a length of webbing  54 , a sensor device  56  and a signaling device  58 . The first and second bracket assemblies  50 ,  52  may each include a base member  62  and an extension member  64  extending from base member  62  and away from back side  24  of rack  12 , as shown in  FIG. 1 . Base member  62  may be secured to mounting apertures  66  on a side portion  68  of legs  30 ,  32 . A fastener, such as a threaded bolt  69 , may be used to secure bracket assemblies  50 ,  52  to mounting apertures  66 , as also shown in  FIG. 1 . 
     In an alternative configuration, the safety and positioning device  10  may include first and second bracket assemblies  50 ′,  52 ′, as shown in  FIG. 2 . Bracket assemblies  50 ′,  52 ′ may each include a sleeve  70  configured to have a shape corresponding to the C-channel configuration  38  of legs  30 - 36  such that a pair of sleeves  70  can be slidably received over each of legs  30 ,  32 . Sleeve  70  may further include a spring loaded pin assembly  72  arranged to be received in one of a plurality of apertures  73  spaced along a side  74  of each of legs  30 ,  32  so as to position first and second bracket assemblies  50 ′,  52 ′ in a desired position or height relative to base  18 . 
     Bracket assemblies  50 ,  52 ′ may use extension members  64  as described above, or may alternatively each use a telescoping extension member arrangement  64 ′. Telescoping extension arrangement  64 ′ may include a first bracket member  78  and a second bracket member  80  arranged to be slidably received in first bracket member  78  in a telescoping fashion. First bracket member  78  may include an aperture  84  and second bracket member  80  may include a plurality of apertures  86  where each one of the plurality of apertures  86  are arranged to align with aperture  84  as the second bracket member is slidably moved toward or away from the back side  24  of rack  12 . The telescoping extension member arrangement  64 ′ may therefore be utilized to position an end  88  of second bracket member  80  at various positions relative to back side  24 . 
     The length of webbing  54  may include a polyester woven webbing material such as the material used in a conventional seat belt application. The webbing  54  can provide the advantages of being wear resistant, flexible and relatively inexpensive. The webbing  54  may be coupled at one end to an adjustment mechanism  90  and at another end to the sensor device  56 . The adjustment mechanism  90  may be secured to one of the extension members  64  and the sensor device  56  may be secured to the other extension members  64  such that webbing  54  extends across the back side  24  of rack  12  from leg  30  to leg  32 . Alternatively, the adjustment mechanism  90  and the sensor device  56  may each be secured to respective ends  88  of second telescoping bracket members  80  of first and second bracket assemblies  50 ′,  52 ′. The webbing may span from leg  30  to leg  32  substantially parallel to back side  24 , or may be positioned to span in a non-parallel configuration using bracket assemblies  50 ′,  52 ′ as may be desired to, for example, accommodate packages with an asymmetric rearward facing configuration. 
     The sensor device  56  may include a tension sensor device  94  arranged to sense a tension in webbing  54  coupled thereto. With particular reference to  FIG. 5 , one non-limiting example of tension sensor device  94  is shown. The tension sensor device  94  may include a housing  96 , a first roller  98 , a second roller  100  and a tension sensor  102 . The webbing  54  may be secured to housing  96  and then routed under first roller  98 , over tension sensor  102 , under second roller  100  and then through an aperture  104  in housing  96 . When a tensile force is imparted onto webbing  54 , a corresponding force is imparted onto tension sensor  102  as the webbing stretches which can be processed into a calibrated output signal for use with signaling device  58 , as will be described in more detail below. The tension sensor device  94  may also include a power input source such as an electrical line  106 . 
     In an alternative configuration, sensor device  56  may include a movement sensing device  110  configured to sense movement of webbing  54 . With particular reference to  FIGS. 2 and 6 , one non-limiting example of movement sensing device  110  is shown and includes a housing  112 , a first and second pair of rollers  114 ,  116 , an optical sensor  117 , and a retractor assembly  118 . Retractor assembly  118  may include an axle  120  for rotatably supporting a roller  122 . A rotatable recoil spring  123  may be wound around axle  120  with one end coupled to axle  120  and another end coupled to an inside of roller  122 , as shown in  FIG. 6 . Webbing  54  can be fed through an aperture  124  in housing  112 , between rollers  114  and  116  and then wound around an outside of roller  122 . Recoil spring  123  may be pre-tensioned and wound around axle  120  in an opposite direction as webbing  54  is wound around roller  122 , such that roller  122  is biased in such a fashion as to impart a predetermined amount of tension on webbing  54  when webbing  54  is attached at an opposite end to one of extension members  64  or  64 ′. In this manner, retractor assembly  118  may be used to provide an amount of length adjustment to webbing  54  by having a suitable amount of webbing  54  wound around roller  122  to span various lengths between legs  30 ,  32 , as well as impart a predetermined amount of tension on webbing  54  as it spans between legs  30 ,  32 . Optical sensor  117  may be configured to sense movement of webbing  54  as it moves or travels between the first and second rollers  114 ,  116 . The optical sensor  117  can be configured to process any sensed movement into a calibrated output signal for transmitting to signaling device  58 , as will be described in more detail below. 
     The tension sensor device  94  can be calibrated to process an amount of tension sensed in webbing  54  in at least three predetermined ranges, including a first or acceptable range, a second or intermediate range outside or beyond the acceptable range, and a third or unacceptable range outside or beyond the second range. Similarly, the movement sensing device  110  can be calibrated to process an amount of movement of the webbing  54  into the same three predetermined ranges, namely the acceptable range, the intermediate range, and the unacceptable range. The predetermined acceptable, intermediate and unacceptable ranges of tension or movement can be correlated to acceptable, intermediate and unacceptable ranges of positions, respectively, of the pallet  14  and/or packages  13  relative to the back side  24  of rack  12 , as will be further described below. It should also be appreciated that devices  94 ,  110  can be calibrated to process fewer or more predetermined amounts of movement or tension. 
     The signaling device  58  can be configured to receive the output signal from either the tension sensor device  94  or movement sensing device  110  via an electrical coupling  126 . Alternatively, signaling device  58  can be configured to wirelessly communicate with tension sensor device  94  or movement sensing device  110 . For example, signaling device  58  can include a radio frequency receiver  127  arranged to communicate with a radio frequency transmitter  128  of the tension sensor or movement sensing devices  94 ,  110 . In this alternative configuration, signaling device  58  can be positioned in locations remote from storage rack  12 , such as in a driver viewable area of forklift  16 . It should be appreciated that multiple signaling devices  58  can also be utilized where, for example, one signaling device  58  is coupled to storage rack  12  and another signaling device  58  is disposed in forklift  16 . 
     The signaling device  58  can include a plurality of externally visible indicators  130  for use in providing visible feedback signals or alerts to a forklift driver or other personnel in proximity to the storage rack  12 . The visible indicators  130  can include, but are not limited to, a power indicator  132 , an indicator  134  illuminated with a green color, an indicator  136  illuminated with a yellow color, and an indicator  138  illuminated with a red color. The signaling device  58  may be configured to illuminate the power indicator when power is received to the signaling device  58 , and may be configured to illuminate visible indicators  134 ,  136 ,  138  when the received output signal corresponds to the acceptable, intermediate, and unacceptable ranges, respectively. 
     Signaling device  58  may additionally include an audible indicator  140  ( FIG. 2 ) for providing an audible alert to the forklift driver or other personnel in proximity to the storage rack  12 . The signaling device  58  can be configured to process the output signal from the tension or movement sensing devices  94 ,  110 , and generate a preconfigured audible alert or message in response to certain conditions. For example, the signaling device  58  can be configured to emit an audible alert via audible indicator  140  when an output signal corresponding to the intermediate range is received and another, different audible alert when an output signal corresponding to the unacceptable range is received. Alternatively, the signaling device can be configured to provide an audible alert only when the output signal received corresponds to the unacceptable range. It should be appreciated that the signaling device  58  can also be configured with information display features and fewer or more visual and audible alert indicators than described above. For example, signaling device  58  could also be configured to include a display device where status information regarding pallet positioning in connection with multiple storage racks  12  is displayed. 
     In operation, the safety and positioning device  10  can be configured for coupling to rack  12  via first and second bracket assemblies  50 ,  52  or  50 ′,  52 ′, respectively. Once coupled, the webbing  54  can span across a back side  24  of rack  12  as shown, for example, in  FIGS. 1 and 2 . The webbing  54  can be adjusted to a desired position relative to base  18  depending on various package and pallet sizes that may be desired to be positioned on rack  12 . For example, webbing  54  may be adjusted vertically relative to base  18  to accommodate particularly short packages by positioning base members  62  or sleeves  70  at an appropriate position on legs  30 ,  32  such that the short package would contact webbing  54  when placed on base  18  and advanced sufficiently rearward. 
     In addition, a horizontal position of the webbing may be adjusted to also accommodate various pallet and/or package depth sizes by adjusting telescoping bracket members  64 ′ toward or away from base  18 . It should also be appreciated that multiple safety and positioning devices  10  can be coupled to legs  30 ,  32  as may be desired, for example, to accommodate packages of various sizes and/or shapes while reducing a need to adjust the position of webbing  54  as described above. 
     With particular reference to  FIGS. 3 and 4 , operation of the safety and positioning device  10  will be further described. As pallet  14  with packages  13  is received in rack  12 , the pallet  14  can be advanced from the front side  22  to the back side  24  while observing signaling device  58 . When the pallet  14  and packages  13  are advanced to a first position  150  so as to contact webbing  54 , an initial amount of tension can be generated in the webbing  54  and sensed by tension sensor device  94 . Alternatively, an initial amount of movement of the webbing  54  can be generated relative to movement sensing device  110 . The initial amount of tension or movement generated in webbing  54  at first position  150  can be correlated to a predetermined amount of tension or movement associated with an end or threshold of the acceptable position range described above. The tension or movement sensing devices  94 ,  110  can generate an output signal to the signaling device  58  to illuminate the green indicator  134  when the webbing  54  experiences the predetermined amount of tension or movement associated with first position  150 . 
     Alternatively, the tension or movement sensing devices  94 ,  110  can be calibrated to generate an output signal to illuminate green indicator  134  until an amount of tension or movement is generated in webbing  54  beyond the calibrated acceptable range of tension or movement, at which time the green indicator  134  would be turned off and the yellow indicator  136  would be illuminated. 
     Illumination of the green indicator  134  provides positive visual confirmation that the pallet is in a predetermined proper position range relative to the front and back sides  22 ,  24  of base  18 . Such an indication is particularly useful when pallet  14  contains large packages or other items that can obstruct a forklift driver&#39;s view of rack  12  or where the pallet is being placed in a multiple level rack on a base that is above the forklift driver&#39;s line of sight. 
     If the pallet  14  is further advanced toward the back side  24  of rack  12 , the pallet  14  can move from the first position  150  to a second threshold position  152  where a further amount of tension or movement is generated in webbing  54 . The tension or movement sensing devices  94 ,  110  can be calibrated to process the further amount of tension or movement generated in webbing  54  from first position  150  to second position  152  to correspond to the predetermined intermediate acceptable position range described above and generate an output signal to the signaling device  58  to illuminate the yellow indicator  136 . 
     Illumination of the yellow indicator  136  provides a visible indication that the pallet  14  has been placed or advanced beyond the predetermined acceptable position range or distance from the back side  24  of rack  12  and can be approaching the predetermined unacceptable position range. Upon movement of the pallet beyond the predetermined acceptable range of tension or movement of the webbing  54  (i.e., beyond position  150 ), the green indicator  134  can be turned off and the yellow indicator  136  can be illuminated as described above. 
     Continued movement of pallet  14  from the second position  152  to a third threshold position  154  can generate an additional amount of tension or movement in webbing  54 , as generally shown in  FIG. 3 . The tension or movement sensing devices  94 ,  110  can be calibrated to process the additional amount of tension or movement generated in webbing  54  from second position  152  to third position  154  to correspond to the predetermined unacceptable position range described above and generate an output signal to the signaling device  58  to illuminate the red indicator  138 . Upon movement of the pallet beyond the predetermined intermediate range of tension or movement of the webbing  54  (i.e., beyond position  152 ), the yellow indicator  136  can be turned off and the red indicator  138  can be illuminated as described above. 
     Illumination of the red indicator  138  provides a positive visual indication that the pallet  14  is in a predetermined unacceptable position range relative to at least the back side  24  of base  18 . The pallet  14  can then be moved in an opposite direction toward the front side  22  so as to place pallet  14  in at least the intermediate position range between first and second positions  150 ,  152  and preferably the acceptable position range (i.e., between back side  24  and position  150 ). Upon such movement, the red indicator  138  can be turned off and either the yellow or green indicators  136 ,  134  can be illuminated depending on the placement of pallet  14  relative to the intermediate and acceptable position ranges, respectively. 
     In addition, the safety and positioning device  10  can be configured such that webbing  54  can no longer stretch or expand in tension, or move relative to movement device  110 , upon tension or movement of webbing  54  to a predetermined limit of the unacceptable range, as generally indicated by third position  154  in  FIG. 3 . With such a configuration, the safety and positioning device  10  can additionally provide a positive stop or retention feature to substantially prevent pallet  14  from being further advanced beyond a limit of the unacceptable range or distance (i.e., beyond third position  154 ) from back side  24  of rack  12 . 
     While one or more specific examples have been described and illustrated, it will be understood by those skilled in the art that various changes may be made and equivalence may be substituted for elements thereof without departing from the scope of the present teachings as defined in the claims. Furthermore, the mixing and matching of features, elements and/or functions between various examples may be expressly contemplated herein so that one skilled in the art would appreciate from the present teachings that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise above. Moreover, many modifications may be made to adapt a particular situation or material to the present teachings without departing from the essential scope thereof.