Telescoping Dunnage Rack for High-Capacity Part Access
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Solution Overview
Problem
Conventional transportable racks used in assembly lines are limited in height and number due to accessibility and space constraints, leading to frequent refilling and reduced part availability, which increases operational inefficiencies.
Innovation Solution
An adjustable rack assembly with a base frame and extension frame, where the extension frame is slidably mounted and actuated to change between collapsed and extended positions, allowing for increased storage capacity and accessibility by accommodating the movement of parts from both lower and upper compartments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the rack height is increased to store more parts, then the storage capacity is improved, but the accessibility by average workers deteriorates
Solution Approach 1:
The rack incorporates a telescoping mechanism with base and extension frames that can dynamically adjust between retracted and extended positions. This dynamic structure allows the rack to transform from a compact, accessible height to a taller configuration for increased storage, then return to the original height for worker accessibility during part retrieval operations.
2Quantity of substance
If the number of racks on the line is increased to provide more parts, then the part availability is improved, but the available space and transport capacity deteriorates
Solution Approach 1:
The rack design features a nested telescoping structure where the extension frame contains compartments that can slide within the base frame compartments. This nesting allows the system to expand storage capacity outward when needed while maintaining a compact footprint when retracted, effectively providing more parts without proportionally increasing the space occupied.
3Productivity
If the rack height is increased to reduce refilling frequency, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The rack is divided into modular segments: a base frame with first compartments and an extension frame with second compartments. Each segment can be independently configured and the extension frame can be added or removed based on storage needs. This segmentation allows the system to achieve increased capacity without permanently complicating the basic rack structure.
Data Source
AI summary
An adjustable rack assembly includes a base frame defining an upper end and an open front side and an extension frame defining an upper end, a bottom end and an open front side. The extension frame is slidably mounted to the base frame. The assembly further includes an actuator coupled between the base frame and the extension frame and operable to move the extension frame between a collapsed position and an extended position. A compartment unit is supported by the extension frame and is at least partially collapsible to accommodate the movement of the extension frame between the collapsed position and the extended position.