Design

Lock, release, cradle, retrieve.

The final Composite Carrier verification prototype combines a compact mechanical latch with a pulley release and removable Genie dolly attachment.

Rotary latch assembly

The latch uses paired locking cams and torsion springs to automatically retain the roll support rod after insertion. Blocking pins constrain motion and shoulder bolts serve as the principal cam pivots. The assembly is mounted to the existing rack structure.

Passive lockingMechanicalRack mounted

Annotated rotary latch CAD
Annotated latch CAD from the final design documentation.
Annotated Genie dolly attachment CAD
Custom Genie dolly attachment with fork sleeves, 5 ft extension, support members, and foldable cradle.

Genie dolly attachment

The attachment slides over the existing Genie forks and provides a defined load path from the composite roll to the dolly. A foldable cradle improves storage when the attachment is not in use, while the long extension reaches into the rack to support elevated rolls.

The design intentionally avoids electrical actuation and instead relies on geometry, springs, and direct operator control.

Key design requirements

NeedDesign response
Safe heavy-load storageMechanical latch retention and robust metal components.
No ladder for accessGround-level pulley release plus Genie dolly retrieval.
Compatibility with lab spaceAttachment sized around the existing racks and dolly.
Simple manufacturingWaterjet-cut latch plates, standard hardware, welded steel attachment.
Low maintenanceNo motors, controls, sensors, or powered locking system.