Lockable Crossbar Assemblies for Shipping Container Access
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Solution Overview
Problem
Existing shipping containers with crossbar assemblies are difficult to access, leading to ergonomic issues for line workers, such as strain and injury, and the crossbar assemblies can move during shipment, causing noise and potential damage.
Innovation Solution
A container with lockable crossbar assemblies that can be secured in desired locations using inter-engaging locking pins and tracks, allowing for easy access and reducing worker strain, while preventing movement during shipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are designed with fixed crossbar assemblies, then structural stability is maintained, but access efficiency deteriorates as workers must walk around or lean into containers to remove parts
Solution Approach 1:
The crossbar assemblies are designed to be movable along tracks within the container rather than fixed, allowing workers to access parts from the front without walking around or leaning in. The crossbars can be repositioned dynamically to provide optimal access points while maintaining structural stability during shipment.
Solution Approach 2:
Tracks are introduced as intermediary elements that guide and constrain the movement of crossbar assemblies. The tracks provide a structured path for crossbar movement while working in conjunction with locking mechanisms to ensure stability when positioned, thus mediating between mobility needs and structural requirements.
2Ease of operation
If turntables are installed to enable container rotation, then access to parts improves, but production cost increases and floor space is consumed
Solution Approach 1:
The rotational function traditionally provided by turntables is extracted and redistributed to individual crossbar assemblies. Each crossbar can be independently moved along its track to the desired position, eliminating the need for a centralized turntable mechanism while maintaining part accessibility.
Solution Approach 2:
Instead of a single rotational mechanism for the entire container, the access function is segmented into multiple independent crossbar assemblies that can be positioned individually. This segmentation allows selective movement of only the crossbars needed for accessing specific parts, reducing overall system complexity and cost.
3Ease of operation
If crossbar assemblies are made movable for better access, then worker ergonomics improve, but noise and potential damage during shipment increase
Solution Approach 1:
The crossbar assemblies are designed with a dual-state system: movable along tracks during loading/unloading operations to improve ergonomics, and lockable in fixed positions during shipment to prevent noise and damage. This dynamic capability allows the system to adapt its behavior based on operational requirements.
Solution Approach 2:
Locking mechanisms are provided that can be engaged in advance before shipment to secure crossbar assemblies in their final positions. This preliminary locking action prevents unwanted movement, noise, and potential damage during the shipping phase while allowing easy repositioning when needed for access.
4Loss of time
If containers are shortened to eliminate worker walking around, then access time is reduced, but shipping capacity decreases
Solution Approach 1:
Crossbar assemblies can be moved along extended tracks to the front of the container, allowing workers to access parts from the front without walking around. This dynamic positioning capability enables access time reduction while maintaining full container length and shipping capacity.
Solution Approach 2:
Tracks extend the full length of the container, serving as intermediaries that allow crossbar assemblies to reach the front even in long containers. This intermediary structure enables workers to access parts quickly from the front while the container maintains its full shipping capacity.
Data Source
AI summary
A container for holding product therein during shipment and for reuse has multiple levels of tracks supported by each side of the container. At least one of the tracks on each side may be linear, generally U-shaped and/or L-shaped. Dunnage supports and at least one lockable crossbar assembly travel along corresponding tracks at the same level. At least one lockable crossbar assembly has locking assemblies to fix the position of the lockable crossbar assembly relative to the tracks. Dunnage hangs from at least some of the dunnage supports for supporting products.