Rack Design

The Design and Layout of a Rack is Critical

Whether its a New Rack or an existing rack that needs improvement, the design intent and part layout of the rack is the most important aspect of a rack build. Selection of materials, size, shape, and location are some of the more obvious factors but it really comes down to the less obvious like two bolts instead of one or rounded edges on all corners. Each rack is unique so these factors are important to call out and design into the rack for optimal performance and longevity. The last thing we want is to have a rack go to waste after only a few months service.

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Materials

The specific kind of materials a rack will be built from always depends on the plating process the rack is used for. It often requires a copper frame and stainless hooks or clips. The temper and grade of the metals used will be critical for strength, longevity, and current flow.

Two bolts instead of one

This might seem like a no brainer but often times rack companies will use only one bolt and then weld some kind of stiffener onto the rack to hold things in place. That is a quick way to damage the integrity of the metal. PTS uses two bolts to secure copper connections.

Part Placement/Layout

The parts on a rack depend on one another to achieve the proper plating thickness. Often call "density" the distance between all the parts and the exact orientation of certain features on a part will create the best rack layout. Upside down, inside out, angled in/out, needs to be considered for the rack to perform at its best

Solder!

Solder is another step some companies leave out or are not aware of. If a copper connection is not soldered it will have more resistance to current flow. That resistance will create carbon buildup over time and then resist all current flow, probably long before the rack should be replaced.

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Sharp Corners

Simple but important step in making sure a rack lasts is that all corners are rounded/deburred. Opposite of plating, the plastisol coating does not buildup on the corners of parts. It will result in low thickness and eventually a breach where chemicals and plating can leach into the rack and ruin it prematurely.

Large Radius

Whenever possible, use large radius in all formed parts. The sharper the radius, the easier and more likely the part will break where it was bent. It might not be apparent in the first month but after the wire/clip is flexed back and forth enough times it will break.

Waterjet Cutting

PTS utilizes a waterjet to cut most of its parts. A waterjet uses a 60K PSI water stream that is mixed with fine grit sand to cut metal. There is no heat affected zone like with laser or plasma, that allows a waterjet to cut sensitive tempered materials like spring clips. The CNC cutting method ensures repeatability and brings a certain level of efficiency to the fabrication process.

Plastisol Coating

Very often the fact that a rack needs to be coated is utilized in the overall design of the rack. Parts need to have clearance from the coating, sometimes the coating can be used to shield or mask certain areas of a part. In all cases the rack needs to be designed with the coating in mind.