Lockable Crossbar Assembly for Container Dunnage Access
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Solution Overview
Problem
Existing shipping containers are difficult to access, leading to ergonomic challenges and increased risk of injury for line workers, as they often require workers to stretch, reach, or bend to retrieve parts, and lack secure dunnage support systems that prevent movement during transport.
Innovation Solution
A container design featuring non-linear tracks and a lockable crossbar assembly that allows dunnage supports to be secured in a desired location, enabling easier access and reducing ergonomic strain by allowing products to be loaded and unloaded without extending to the rear of the container, while maintaining dunnage stability during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are designed with traditional fixed structures, then manufacturing is simple, but access to products is difficult and requires workers to stretch or reach to the rear of the container
Solution Approach 1:
The crossbar assembly is designed to be movable along tracks rather than fixed, allowing it to be repositioned dynamically. This enables the container structure to adapt to different operational needs while maintaining relative structural simplicity through the use of straightforward linear tracks and sliding mechanisms.
Solution Approach 2:
The container interior is divided into functional zones using movable crossbars that can be positioned at different locations along the tracks. This segmentation allows products to be accessed from multiple positions without requiring workers to reach to the rear, improving ease of operation while keeping individual components simple.
2Productivity
If containers are made longer to accommodate more products, then productivity increases, but workers must walk around the container to access products at the rear
Solution Approach 1:
The movable crossbar assembly allows the container to maintain extended length for higher productivity while enabling workers to access products from the front or side by simply sliding the crossbar to the desired position, eliminating the need to walk around the container.
Solution Approach 2:
The movable crossbar acts as an intermediary structure that can be repositioned to create access pathways. This mediator allows workers to reach products without needing to circumnavigate the container, solving the accessibility problem in longer container configurations.
3Ease of operation
If dunnage supports are made movable to improve access, then ease of operation increases, but dunnage may move during transport creating noise and damage
Solution Approach 1:
The crossbar assembly transitions from a static to a dynamic structure that can be locked in place during transport to ensure reliability, and moved freely during loading and unloading operations to improve ease of operation. This dynamic locking mechanism resolves the contradiction between mobility and stability.
Solution Approach 2:
The crossbar assembly is pre-configured with locking mechanisms that can be engaged before transport begins. This preliminary action ensures dunnage stability during shipping while allowing easy movement during operational phases when locks are disengaged.
4Ease of operation
If turntables are installed to enable container rotation for better access, then ease of operation improves, but production cost increases and floor space is consumed
Solution Approach 1:
Instead of rotating the entire container on a turntable, the crossbar assembly is made movable along fixed tracks. This dynamic repositioning achieves similar access improvements without requiring complex rotation mechanisms, reducing production costs and eliminating the need for additional floor space.
Solution Approach 2:
The rotation function is extracted from the container itself and transferred to the crossbar assembly. Rather than rotating the whole container, only the necessary crossbar portion is moved along tracks, simplifying the overall system and eliminating the need for turntables and associated infrastructure.
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 dunnage supports extending between corresponding tracks at the same level. At least one lockable crossbar assembly has one or more locking assemblies to fix the position of the lockable crossbar assembly relative to the tracks. Dunnage may hang from the dunnage supports for supporting products during storage or shipment.