Flow rack design systems and methods

A method of providing a flow rack system design using a flow rack design application is provided. The method includes selecting a first tier menu item from a plurality of first tier menu items saved in memory using a computer. A second tier menu item is selected, wherein the second tier menu item has project level standards information associated with the second tier menu item saved in memory. A virtual flow rack system is generated using the computer, the project level standards information and parts information saved in memory.

TECHNICAL FIELD

The present specification generally relates to computer-aided design systems and, more particularly, to computer-aided flow rack design systems and methods.

BACKGROUND

Flow racks are commonly used to store and/or transfer components, parts, etc. The flow racks may have a plurality of rollers so that components and/or component trays can be moved from one location to another location. Such racks can facilitate movement of the components and/or component trays from one location to another.

Plants, warehouses and other locations have their own space limitations or constraints. Flow racks may be designed to take into account such space constraints. Human factors and efficiencies may also be considered. Flow rack design systems and methods are needed that facilitate flow rack design, taking into account various factors, such as space limitations and ergonomics.

SUMMARY

In one embodiment, a method of providing a flow rack system design using a flow rack design application is provided. The method includes selecting a first tier menu item from a plurality of first tier menu items saved in a database memory using a computer. Each first tier menu item has location level standards information associated therewith. The location level standards information are associated with a preselected geographic location. A second tier menu item is added wherein the second tier menu item includes the location level standards information by default. The location level standards information is modified thereby generating project level standards information associated with the second tier menu item and the project level standards information is saved in the database memory. A parts list including parts information is utilized. A virtual flow rack system is generated using the computer, the parts information and the project level standards information.

In another embodiment, a method of providing a flow rack system design using a flow rack design application is provided. The method includes selecting a first tier menu item from a plurality of first tier menu items saved in memory using a computer. A second tier menu item is selected, wherein the second tier menu item has project level standards information associated with the second tier menu item saved in memory. A virtual flow rack system is generated using the computer, the project level standards information and parts information saved in memory.

In another embodiment, a method of providing a flow rack system design using a flow rack design application is provided. The method includes importing a part list into the flow rack design application. A preview image of a virtual flow rack system is generated using a computer and the flow rack design application. The flow rack design application uses standards information and parts information saved in memory in generating the preview image. An obstacle is displayed in the preview image.

DETAILED DESCRIPTION

Embodiments described herein generally relate to computer-aided flow rack design systems and methods. The flow rack design systems and methods described herein can enable a designer to create or update a virtual flow rack design that can be tailored to its environment or improved in a continuous or intermittent fashion, while keeping design particulars in the hands of the designer. The flow rack design systems and methods allow more emphasis on process flow, human factors and efficiencies when designing and building flow racks that will be used to store and position items on a plant floor or other location. A hierarchical standards approach may be utilized, which can reduce the need for mass input and the ability for quick changes and adjustments is enhanced, as will be described in greater detail below.

Referring toFIG. 1, a computer and software-based method10of providing a flow rack system design is illustrated. At step12, a designer selects a first tier menu item, sometimes referred to as a location identifier, from a plurality of first tier menu items saved in a database memory using a computer. Each first tier menu item may have location level standards information associated therewith. As used herein, “standards information” refers to parameters (e.g., rack spacing, box clearance, rack height, etc.) in design of a particular flow rack system and/or its environment, such as within a plant, warehouse or other facility. As will be described, the parameters may be location specific (location level), specific to a project (project level) or independent/customized (rack and shelf level) or any combination thereof. The location level may relate to overall general standards, the project level may relate to a particular project standards and the rack and shelf level (sometimes referred to as line level) may relate to particular section standards. Thus, a three tier standards system may be provided where a user can customize a flow rack system design for a particular use.

Once a first tier menu item is selected, the designer can add or create a second tier menu item, sometimes referred to as a project identifier at step14that is associated or falls within the first tier menu item. Initially, the second tier menu item may have the location level standards information associated therewith by default. Such an arrangement can reduce the amount of data entry required by allowing use of default values that are associated with a particular location. The designer can then modify the location level standards information to generate project level standards information, as needed, associated with the second tier menu item at step16. The project level standards information associated with the second tier menu item can be saved in memory at step18.

Once the project level standards information is generated (and/or the location level standards information by default), which can be used to build the flow rack system, a parts list including parts information saved in memory is identified at step20. The parts list may be available, for example, from a spreadsheet saved in memory and associated with the location associated with the first tier menu item. The parts list may be pre-generated using any suitable spreadsheet application, such as EXCEL®, commercially available from Microsoft Corporation. The parts information and the project level standards may be used to generate a virtual flow rack system at step22using the computer and, for example, a computer-aided design tool, such as AUTOCAD®, commercially available from Autodesk, Inc.

Referring briefly toFIG. 2, a system30for implementing the computer and software-based method including the computer and software-based method10is illustrated as being implemented using a graphical user interface (GUI) that is accessible at a user workstation32(e.g., a computer), an application server34, a database36and associated database server39. While only one application server34is illustrated, the system30can include multiple workstations and application servers containing one or more applications that can be located at geographically diverse locations. In some embodiments, the system30is implemented using a wide area network (WAN), such as an intranet or the Internet. The workstation32may include digital systems and other devices permitting connection to and navigation of the network. Other system30variations allowing for communication between various geographically diverse components are possible. The lines depicted inFIG. 2indicate communication rather than physical connections between the various components.

The system30includes a flow rack design application38that provides functionality for use in capturing, processing and maintaining flow rack design data by allowing the creation, review and approval of virtual flow rack designs. While the flow rack design application38is shown provided by the application server34, the flow rack design application38may be provided locally at each workstation32. The system30may also allow management or control of applications using, e.g., an authentication application to provide system security and/or to assign user permissions.

Referring toFIG. 3, an exemplary standards entry menu40illustrating various design standards is shown for a particular type of modular flow rack system (e.g., such as commercially available from Creform Corporation). As can be seen, fields (e.g., see fields42and44) are provided that display values (standards information) that can be modified by the designer from their defaults or current values (e.g., location or project level). At least some of the fields can be mapped by the flow rack design application38to a visual representation of a flow rack system46to illustrate the dimension of the flow rack system46that the field is associated with. For example, field42(Rack Height Max) is associated with the maximum height of the built flow rack system, without totes, field44(Rack Width) is associated with the maximum width of the built flow rack system, field48(Rack Length Max) is associated with the maximum depth of the built flow rack system and field50(Shelf Angle) is associated with the angle of a shelf relative to horizontal. The fields illustrated are representative and there may be more or less fields allowing for customization of the flow rack system design. For example, in some embodiments, the ability to add, select between and remove casters is provided. The length dimensions shown are in millimeters, but inches may be selected. Conversion and angle calculators may be provided to facilitate units of measurement conversions and determination of shelf angles.

While many of the fields are associated with flow rack system dimensions, other fields may be provided to allow the user to control other parameters. For example, field52(Adj Box Clearance Min) is associated with the minimum distance between totes, field54(Top Clearance Min) is associated with the minimum distance from a top of a tote to the next shelf and field56(Side Clearance Min) is associated with the minimum distance between a tote and a side support structure. Control of such tote parameters can allow spacing for handling of the totes during actual usage of the flow rack system.

FIG. 4illustrates an exemplary project menu60that allows creation or change of group level information, including standards information. Once a location or first tier menu item is selected (see field62), a group identifier or second tier menu item may be selected if one already exists. If a new project is needed, a second tier menu item may be added as shown byFIG. 4.FIG. 5illustrates an example of a form66for defining project settings, such as a project name at field68. It should be noted that a third tier menu item may also be selected under the Line tab. A plant computer-aided design (CAD) file can be identified and located using field70and browse button72. This can allow accessing of the plant CAD file corresponding to the selected location at a later time without additional searching. A parts list file may also be identified using field74and browse button76. By actuating create button78, the parts list file may be opened and the parts information imported into the flow rack design application38.

The parts list for the project may be modified or updated, for example, using an updated parts list. Referring toFIG. 6, an updated parts list can be identified by checking an update data box84and then using the field74and browse button76. Actuating the update button80initiates another import process, similar to the original import process for the original parts list.

The flow rack design application38may be used to compare the original and updated parts lists to highlight any changes for the user. Referring toFIG. 7, an exemplary update report86is illustrated that presents update information from a comparison between the original and updated parts lists. Update information may include, for example, matching parts88, which is a count of the number of parts having no change, a new parts list90that shows any new parts in the updated parts list and a modified parts list92that shows any parts that are modified from the original parts list. If there are one or more parts modifications, the modifications may be reported in a new column94. For example, in new column94, a length of a tote including plugs is illustrated as having changed. Various tote dimensions, standards information and content information (e.g., weight) can be used in building the virtual flow racks, as will be described in greater detail below. A removed parts list96may be provided that reports the total number of parts that have been removed from the original parts list.

Referring toFIG. 8, once the parts information and parts list are imported and updated, if needed, the parts information and standards information may be exported to a design view form100(see alsoFIG. 9). The design view form100includes multiple columns (e.g., see columns102and104) with fields (e.g., see fields106and108) that contain information that may be used by the flow rack design application38in generating a virtual flow rack design including the parts and parts information provided by the parts list. The columns may include design information from different sources, such as information imported directly from the parts list, calculated information (e.g., calculated during the export process by the flow rack design application38), mandatory manual entry/edit information and optional manual entry/edit information. As examples of information imported directly from the parts list, column102(Length) includes the length of the tote for a part, column104(Width) includes the width of the tote for a part and column110(Height) includes the height of the tote for a part. Other examples of information imported directly from the parts list includes column112(Usage per Hour), which can be used to calculate, for example, totes per day (useful for ergonomic reasons), column114(Full Tote Weight) includes weight of the tote with full freight and column116(Empty Tote Weight) includes weight of an empty tote. As examples of calculated information, column115(Full Stacked QTY) calculates how many stacked totes are needed for a given number of totes, column117(Return Stacked QTY) calculates how many stacked return totes are needed for a given number of return totes, column118(Rack Capacity) calculates how many totes can fit on the flow rack and column119(1 Facing 1 Stack) calculates how many totes can fit on the flow rack with all totes facing a single direction in a single stack. Examples of manually entered information include column121(Full Rack #) is the rack number on which the tote is placed, column123(Full Shelf #) is the shelf number on which the tote is to be placed and column125(Full Rows QTY) is the number of facings or rows are desired, which is similar for Return Rows QTY in column139for return totes. The columns illustrated are exemplary and there may be more or less information to be entered, calculated and/or imported.

Referring toFIG. 9, as the design information is being imported, calculated and manually entered, an error checking feature120may be provided that looks for errors. Color coding may be used to highlight the various errors. For example, the lack of a value entered in a mandatory field may cause one or more error indicators, such as red text to be displayed. An errors calculation124may indicate a total number of errors detected.

Ergonomic information may also be displayed to the designer. For example, inFIG. 9a color-coded system using different background field colors (e.g., red, yellow and green) may be used to provide the designer a visual indication of where the various totes should be positioned according to ergonomic standards, such as those provided by the National Institute for Occupational Safety and Health (NIOSH). NIOSH is the federal agency responsible for conducting research and making recommendations for the prevention of work-related injury and illness. In the example ofFIG. 9, the belt assembly126and seat belt retractor cover128totes should be placed within a height range in the flow rack system associated with their color (red) and the bracket130and gusset132totes should be placed within a height range in the flow rack system associated with their color (e.g., yellow). Knowing the ergonomic standards, the designer can manually enter a value, for example, in the fields134(Full Shelf #) that allow for shelf placement of the totes.

Once the design information is imported, calculated and manually entered, the CAD tool may be used to generate a preview image of the flow rack system using the design information. Referring toFIG. 10, the preview image140may be a Portable Document Format (PDF) file that is generated using the CAD tool and displayed adjacent (e.g., above) the parts list and design information. For example, the PDF file may be created from a drawing (DWG) file generated by the CAD tool. The preview image140may be saved in memory, once created, for example, to allow the designer to view the preview image140, even if a CAD tool is unavailable at a particular workstation. The preview image140may be zoomed in and out, panned, rotated and/or printed.

FIG. 11illustrates the preview image140of virtual flow rack system144in isolation. The preview image140includes the virtual flow rack system144and flow rack system information146displayed adjacent the virtual flow rack system144. The virtual flow rack system144includes side support assemblies148and150and shelf assemblies160and162. Various engineering particulars (e.g., location and usage of various support bars, beams, fasteners, etc.) of the side support assemblies148and150and shelf assemblies160and162may be predetermined and built by the CAD tool based on, for example, the number of parts selected and their physical characteristics, such as size, weight and facing. In the illustrated example, a subset (e.g., four) of the parts list154is used to build the virtual flow rack system144. As parts are added (and their associated totes), a refresh button155(FIG. 10) may be used to update the virtual flow rack system144. As can be seen, the belt assembly126and seat belt retractor cover128totes are located on the bottom shelf assembly160and the bracket130and gusset132totes are placed on the upper shelf assembly162. In some embodiments, the totes126,128,130and132each have a color that corresponds to their dictated ergonomic standard. For example, totes126and128may be illustrated red in color and totes130and132may be illustrated yellow in color.

The flow rack system information146is displayed adjacent the virtual flow rack system144. In the illustrated example, the flow rack system information146is shown below the virtual flow rack system144. In other embodiments, the flow rack system information146may be located above or to the side of the virtual flow rack system144. In some embodiments, the flow rack system information146may move locations or move with the virtual flow rack system144as the virtual flow rack system144is moved or manipulated (e.g., rotated, panned, etc.). The flow rack system information may include dimensions of the flow rack system (e.g., length, width and/or height) and dimensions of the shelves (e.g., width and/or height).

Referring now toFIGS. 12 and 13, the flow rack design application38may include an ergonomic guide feature that, when enabled, visually displays an ergonomic guide168adjacent (e.g., behind) the virtual flow rack system144. The ergonomic guide168can provide, for example, height ranges in which particular totes should be placed, based on ergonomic standards information. As one example, the ergonomic guide168may include indicator areas170,172,174,176and178(e.g., in the form of horizontally extending bands) located at different vertical distances. The indicator areas170,172,174,176and178may represent acceptable height ranges in which to locate the totes126,128,130and132based on ergonomic standards. The indicator areas170,172,174,176and178may also be color-coded. In the illustrated embodiment, the indicator areas170,172,174,176and178include a color that corresponds to or matches the available colors of the totes126,128,130and132to provide the designer an indication of where the totes should be placed according to the ergonomic standards. For example, indicator areas170and178may be red, indicator areas172and176may be yellow and indicator area174may be green. In this example, green totes should be placed at least partially within indicator area174(green), yellow totes (e.g., such as totes130and132) should be placed at least partially within indicator areas172,176or174(yellow or green) and red totes (e.g., such as totes126and128) may be placed within any of the indicator areas170,172,174,176and178. Based on the tote arrangement of the virtual flow rack system144, the designer can modify the current design. For example,FIG. 14illustrates a modification of the virtual flow rack system144with the totes126and128turned length facing, which, in this instance, can improve density of the virtual flow rack system144, while maintaining ergonomic standards.

The flow rack design application38may also provide the ability to design for the handling of return totes. For example, referring toFIG. 15, the virtual flow rack system144is modified to handle tote returns180,182,184and186. The tote returns180,182,184and186represent emptied totes126,128,130and132. By selecting an add returns feature, the flow rack design application38widens the virtual flow rack system144and adds a shelf assembly188for receiving the tote returns180,182,184and186.

Referring toFIG. 16, a form190(Rack Special Conditions) may be provided that allows for modification of the size and shape of the virtual flow rack system144(e.g., from the default, location level standards information and/or project level standards information) after generation of the virtual flow rack system144. For example, field192(Rack Length) allows the designer to enter a length value for all racks in a rack list194and field196(Rack Type) allows for selection of a flow rack system type from multiple flow rack system types. The form190also allows for individual flow rack system modifications. For example, field198(Rack #) indicates which flow rack system is being modified, field200(Length) allows for modification of the length of a specific flow rack system, field202(Width) allows for modification of the width of a specific flow rack system and field204(Height) allows for modification of the height of a specific flow rack system. Field206(Face Angle) allows the designer to change the angle of the face of a specific flow rack system (seeFIG. 3), field208(Bottom Height) allows the designer to set the spacing of the bottom shelf from the floor of a specific flow rack system and field210(Space Before) can be used to provide space, e.g., for equipment and other obstacles such as columns, beams, etc. In some embodiments, obstructions213may be illustrated in the preview image140(FIG. 10) to provide the designer a visual representation of the location of the flow rack system relative to the obstruction. Referring briefly toFIG. 17, another form212(Shelf Special Conditions) may be provided that allows for modification of each shelf angle individually, by rack, or as a whole.

Referring toFIG. 18, the flow rack design application38may automatically generate a bill of materials214, during or after the virtual flow rack system is designed, based on flow rack parts information saved in memory. The bill of materials214may include all parts, such as support legs, shelf supports, fasteners, couplings, etc. needed to build a particular flow rack system. The bill of materials214may not only include dimensional information, but also pricing information such that a total price can be calculated by the flow rack design application for a particular flow rack system.

The above-described computer-aided flow rack design systems and methods enable a designer to create or update a virtual flow rack design that can be tailored to its environment or improved in a continuous or intermittent fashion, while keeping design particulars in the hands of the designer. Relatively short design times can be used in creating a virtual flow rack design that meets manufacturing and ergonomic needs. A CAD tool can be used to generate a virtual representation of the flow rack system, which can then be modified by the designer and refreshed to update the virtual flow rack system. Environmental conditions, such as equipment or other obstacles can be taken into account in the virtual flow rack design and even visually represented to give the designer a visual indication of suitability of the virtual flow rack design in its particular environment.