Automotive Frame Stacking with Nested HDPE Spacers
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Solution Overview
Problem
The existing methods for loading automotive vehicle frames on railroad cars are space-limited, leading to inefficiencies in transporting multiple frames within a given volume, resulting in increased costs due to the need for additional vehicles to accommodate more frames.
Innovation Solution
The strategic arrangement of vehicle frames in alternating end-for-end and lateral offset configurations, combined with the use of molded plastic spacers that nest and interfit, allows for optimized stacking and increased density within a given volume, utilizing computer-aided design to determine the most efficient spatial relationships and create custom dunnage elements for maximum volumetric utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If frames are stacked vertically using traditional pin bars, then frames can be transported on railroad cars, but the stacking density is low and volume space is not maximized
Solution Approach 1:
The patent implements nesting by placing spacers within the hollow interior spaces of vehicle frames, and positioning frames within stacks defined by dunnage elements. This nested arrangement allows multiple frames to occupy overlapping spatial volumes, dramatically increasing stacking density from traditional vertical stacking to a configuration where frames are embedded within each other's structural voids
Solution Approach 2:
The patent transitions from one-dimensional vertical stacking to three-dimensional spatial utilization by arranging frames in multiple dimensions simultaneously. Frames are positioned not only vertically but also horizontally offset and angled relative to one another, creating a multi-dimensional stacking configuration that maximizes the use of available transportation volume
2Productivity
If more frames are loaded to maximize space utilization, then transportation cost per frame decreases, but the stacking arrangement becomes more complex and difficult to secure
Solution Approach 1:
The patent applies universality by designing dunnage elements and spacers that perform multiple functions simultaneously: they provide structural support for stacking, define precise spatial relationships between frames, enable securement points for straps, and utilize the hollow spaces within frames for additional frame placement. This multi-functionality reduces the need for separate components for each function
Solution Approach 2:
The patent implements preliminary action by pre-configuring dunnage elements and spacers with integrated features such as pre-formed attachment points, pre-positioned geometric configurations, and pre-integrated hollow space structures. These pre-configured elements eliminate the need for complex on-site arrangement and securing operations
Data Source
AI summary
A method and apparatus for increasing the volumetric efficiency with which automotive vehicle frames are stacked on a carrier such as a railroad flat car. Frames are alternately reversed end-for-end and/or laterally offset from one another and may be longitudinally angled and internested between adjacent stacks. Twin sheet molded HDPE spacers are used.