Lockable Crossbar Assembly for Ergonomic Shipping Container Access
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Solution Overview
Problem
Existing shipping containers are ergonomically unfriendly, causing strain and injury to workers due to difficult access and movement of parts, and they lack a secure mechanism to keep dunnage supports in place during transport, leading to noise and potential damage.
Innovation Solution
A container with a lockable crossbar assembly that moves along non-linear tracks, allowing for secure positioning and easy access to products without requiring workers to stretch or bend excessively, and a mechanism to keep dunnage supports in the upper tracks during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are designed with fixed structure and no movable components, then manufacturing cost is reduced and structure is simpler, but worker access to parts is difficult and time-consuming
Solution Approach 1:
The patent applies the dynamics principle by making the crossbar assembly movable along non-linear tracks rather than fixed. The crossbar can be repositioned between locked and unlocked positions, allowing workers to access parts from the front of the container without needing to walk around it or perform awkward bending motions, thereby improving ease of operation while maintaining reasonable structural complexity
Solution Approach 2:
The container structure is segmented into functional components: the crossbar assembly that can move independently along the tracks, the locking mechanism that allows positional control, and the track system that provides guidance. This segmentation enables the crossbar to be repositioned to optimize worker access while keeping the rest of the container structure simple and fixed
2Productivity
If containers are made longer to allow worker access from front, then productivity is improved, but more space is required in the container for parts
Solution Approach 1:
The movable crossbar assembly allows the container to maintain a compact length while still providing excellent worker access. By repositioning the crossbar along the non-linear tracks, workers can access parts from the front without needing the container to be excessively long, thus improving productivity while minimizing the volume required for parts storage
Solution Approach 2:
The non-linear tracks allow the crossbar to move in multiple dimensions (both linear and vertical movement), enabling workers to access parts from the front of the container without requiring increased linear length. The vertical component of the track path allows the crossbar to position parts at ergonomic heights while maintaining a compact container footprint
3Ease of operation
If dunnage supports are made movable along tracks, then ease of operation is improved, but dunnage may move during transport causing noise and damage
Solution Approach 1:
The locking mechanism extracts the stability function from the movable crossbar assembly. When the crossbar is in the locked position, the locking mechanism engages with the track to prevent any movement of the dunnage supports, thereby eliminating noise and potential damage during transport while still allowing repositioning when needed
Solution Approach 2:
The system dynamically switches between two states: movable (when unlocked for repositioning dunnage) and locked (when stability is required during transport). The locking mechanism provides a reliable way to transition from the dynamic state to the stable state, ensuring dunnage remains fixed during transport while maintaining ease of operation when repositioning is needed
4Object-affected harmful factors
If workers must bend and reach into containers to remove parts, then container structure can be simpler, but worker injury and strain increase
Solution Approach 1:
The movable crossbar assembly dynamically repositions parts to ergonomic locations accessible from the front of the container. By moving the crossbar along non-linear tracks that include vertical components, parts can be brought to the worker's natural working height and position, eliminating the need to bend and reach, thus reducing worker strain and injury while maintaining reasonable structural complexity
Solution Approach 2:
The non-linear tracks enable movement in both horizontal and vertical dimensions, allowing the crossbar to position parts at ergonomically correct heights and locations. This multi-dimensional movement capability ensures parts are always accessible to workers without requiring bending or excessive reaching, directly addressing worker safety while adding only moderate structural complexity
Data Source
AI summary
A container for holding product therein during shipment and being returned for reuse has at least one track supported by each side of the container. The container has at least one lockable crossbar assembly extending between opposed tracks. Each lockable crossbar assembly has one or more locking assemblies to fix the position of the lockable crossbar assembly relative to the tracks.