Autorack Deck Repositioning via Cross-Brace Assembly
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Solution Overview
Problem
Automobile manufacturers face challenges in efficiently reconfiguring autoracks to adapt to changing market demands, leading to shortages and the need for new equipment, as existing autoracks are not easily convertible between different configurations, and the replacement of flatcars necessitates recertification, resulting in inefficiencies and increased costs.
Innovation Solution
A system and method for reconfiguring autoracks by removing and repositioning decks, installing cross-brace assemblies, and using actuators and controllers to adjust deck and roof positions, allowing for conversion between tri-level, bi-level, and convertible configurations, thereby extending the life of autoracks and reducing the need for new equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If autoracks are designed as non-convertible fixed configurations, then manufacturing and initial deployment are simpler, but adaptability to changing market demands deteriorates
Solution Approach 1:
The patent applies the dynamics principle by making the autorack configuration changeable over time. Decks are designed to be removable and repositionable, allowing the autorack to transition between different configurations (e.g., tri-level to bi-level) based on market demands. This dynamic design enables the same physical infrastructure to adapt to varying transportation needs without requiring new equipment.
Solution Approach 2:
The patent applies segmentation by dividing the autorack into modular components - specifically, decks that can be independently removed and repositioned. This modular approach allows selective reconfiguration of the autorack structure, enabling operators to adjust capacity and configuration by moving individual decks rather than replacing entire structures.
2Reliability
If flatcars are replaced due to aging, then safety and reliability are improved, but recertification time and cost increase
Solution Approach 1:
The patent applies segmentation by separating the flatcar replacement process from the rack recertification process. By designing the rack as a removable module that can be transferred to a new flatcar, the system allows the rack to be recertified independently without requiring complete autorack downtime. This modular replacement approach reduces the time loss associated with recertification.
Solution Approach 2:
The patent applies preliminary action by preparing replacement flatcars and racks in advance. The system allows for proactive replacement where a new flatcar can be positioned and the rack transferred before the old flatcar completely fails, minimizing operational disruption and recertification time.
3Adaptability or versatility
If new equipment is purchased to meet changing demand, then supply adequacy is improved, but investment cost increases
Solution Approach 1:
The patent applies universality by designing the autorack rack to perform multiple functions across different configurations. A single rack structure can be reconfigured to provide different capacity levels (tri-level, bi-level) to meet varying market demands. This multi-functionality eliminates the need to purchase separate dedicated equipment for different market conditions, reducing investment costs while maintaining supply adequacy.
4Adaptability or versatility
If decks are removed and repositioned for reconfiguration, then adaptability is improved, but structural integrity challenges arise
Solution Approach 1:
The patent applies dynamics by designing connection mechanisms that allow decks to be dynamically attached and detached while maintaining structural integrity during operation. The connection system enables safe reconfiguration when needed while ensuring robust attachment during vehicle transport, balancing adaptability with structural strength requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and cost-effective conversion of autoracks to match changing market demands, extends the life of autorack components, and reduces the time and cost associated with recertification, allowing for efficient use of existing equipment.
Implementation Method 1
The actuator is operable to pull the cable to adjust a vertical position of the deck within the autorack
Implementation Method 2
coupling at least one pulley to the autorack, coupling at least one cable to the at least one pulley
Data Source
AI summary
A method comprises removing a first deck of a plurality of decks and a second deck of the plurality of decks from an autorack. The method further comprises removing one or more of a plurality of posts of the autorack and coupling a cross-brace assembly to one or more of the plurality of posts, wherein the cross-brace assembly is coupled to the one or more of the plurality of posts at a location above an existing brace bay of the autorack. The method also comprises coupling the second deck of the plurality of decks to the autorack at a location above or below the cross-brace assembly.