Self-Leveling Lift-Assisted Decking System for Cargo Trailers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current cargo trailer decking systems require two workers to efficiently position and adjust cross-beams for vertical cargo stacking, which is time-consuming and costly, and lacks the ability to be easily operated by a single worker.

Innovation Solution

A self-leveling lift-assisted deck system with a vertical sliding track system and foot assembly that allows a single operator to adjust beam heights with limited force, using a beam lift stabilizer assembly and sliding foot assembly to maintain beam levelness and secure it at desired positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If two workers manually position cross-beams to desired heights, then the cross-beams can be evenly positioned at selected vertical positions, but the operation becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvebeam positioning precisionVSAvoidtime for beam adjustment

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces the manual mechanical system with a motorized winch system that uses a drum and cable to mechanically lift and position the cross-beam. The winch motor automatically controls the beam's vertical movement, eliminating the need for two workers to manually coordinate positioning while maintaining precise placement at desired heights.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service operation where a single worker can operate the winch control to automatically position the cross-beam. The winch mechanism provides self-contained mechanical advantage through the drum and cable system, allowing one person to perform a task that previously required two workers, thereby reducing both time and labor requirements.

Inventive Principle:

Principle #25Self-service

2Stability of the object's composition

If two workers manually adjust cross-beams, then even positioning is achieved, but labor costs and operational complexity increase

Engineering Contradiction:

Improvebeam levelnessVSAvoidoperational simplicity

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The manual mechanical coordination between two workers is replaced with an automated winch system that uses a motorized drum and cable to control beam movement. This substitution maintains the beam's levelness through controlled mechanical lifting while dramatically simplifying operation to require only one worker operating the winch control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The winch system acts as an intermediary mechanism between the operator and the cross-beam. The drum and cable system provides controlled mechanical advantage, mediating the force application to achieve smooth, level positioning of the beam without requiring direct manual handling by multiple workers, thus simplifying the operation while maintaining stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If manual methods are used to position cross-beams, then equipment complexity is reduced, but productivity and operational efficiency decrease

Engineering Contradiction:

Improvedecking system complexityVSAvoidcargo stacking efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent introduces a motorized winch system with drum and cable mechanism to replace manual positioning methods. This mechanical substitution adds some device complexity but dramatically improves productivity by enabling a single worker to quickly and efficiently position cross-beams at desired heights, thereby increasing cargo stacking efficiency and operational throughput.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The winch system provides self-service capability where the motorized mechanism automatically performs the lifting and positioning work that would otherwise require significant manual effort from multiple workers. This automation increases productivity by enabling rapid beam adjustment while maintaining relatively simple overall system design through the use of standard winch components.

Inventive Principle:

Principle #25Self-service

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 efficient and solo operation of adjusting cross-beams to various heights within a cargo trailer, reducing the time and labor required for vertical cargo stacking, enhancing operational efficiency and revenue opportunities.

Implementation Method 1

a beam lift stabilizer assembly positioned within the beam and operable to lift and lower the beam to selected vertical positions

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Implementation Method 2

The foot assembly contains a spring-loaded stop that engages the track

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS8979451B2Self-leveling lift-assisted decking system for use in a cargo trailer

Publication Date: 2015.03.17 DOWNING STEVEN E

AI summary

An improved captive beam decking system is disclosed for use in a cargo trailer. The system includes a beam assembly and a foot assembly that is selectively engagable to a vertical sliding track system. The sliding track system is attached to the sidewall of a trailer vertically. The beam can be easily moved at different heights that are selected based upon the configuration of the cargo trailer.