Movable Dunnage Supports on Non-Linear Tracks

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Solution Overview

Problem

Existing container designs for shipping parts in the automotive industry are ergonomically unfriendly, requiring workers to walk around or bend to access products, leading to strain and increased risk of injury, which can result in lost production time and higher shipping costs due to reduced container capacity.

Innovation Solution

A container with movable dunnage supports and tracks that allow products to be easily loaded and unloaded from a front position, reducing the need for workers to stretch or bend, and enabling efficient movement of dunnage supports to create an ergonomically friendly access zone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the container is designed with fixed dunnage supports, then the container structure is simple and stable, but workers must walk around or bend to access products, causing ergonomic strain and reduced productivity

Engineering Contradiction:

Improveergonomic access to productsVSAvoidcontainer structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The dunnage supports are designed to be movable along non-linear tracks rather than fixed, allowing them to dynamically adjust position. The tracks include vertical and horizontal sections that guide the dunnage supports through controlled movement paths, transforming the static container interior into a dynamic system that adapts to worker needs and improves ergonomics

Inventive Principle:

Principle #15Dynamics

2Productivity

If the container length is reduced to eliminate the need for workers to walk around, then productivity improves and injury risk decreases, but the container capacity to ship parts is reduced

Engineering Contradiction:

Improveparts removal efficiencyVSAvoidcontainer cargo capacity

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The non-linear tracks extend in multiple dimensions (vertical and horizontal) rather than simply lengthening the container in one direction. This multi-dimensional approach allows workers to access products from a compact footprint while the dunnage supports move through extended three-dimensional paths, effectively increasing accessible capacity without proportionally increasing container length

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of operation

If workers repeatedly bend and reach into the container to insert or remove parts, then parts can be accessed, but physical trauma and pain result leading to lost production time

Engineering Contradiction:

Improveparts insertion and removalVSAvoidworker health and production continuity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The dunnage supports can be pre-positioned along the tracks to bring products to ergonomic heights before workers need to access them. This preliminary positioning action eliminates the need for workers to repeatedly bend and reach, preventing physical trauma and maintaining production continuity by keeping workers healthy

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3068697B1Container having non-linear tracks for supporting movable dunnage

Publication Date: 2019.02.20 BRADFORD CO

Figure 1
Figure 1A
Figure 1B

AI summary

A container (10) for holding product therein during shipment and being returned for reuse has a frame (12), tracks (60, 72) supported by opposite sides of the frame (12), and a plurality of dunnage supports (70) extending between the tracks. At least one of the tracks (60) on each side is generally U-shaped. Each dunnage support (70) comprises end members (90) and a middle member (92), the end members (90) being movable along the tracks (60, 72). The dunnage supports (70) support dunnage (128) for supporting products (5) for storage or shipment.