Case Study: Audi A5L Brake Caliper Dedicated Transport Rack
Background & Pain Points
In the transportation of Audi A5L brake calipers, traditional methods face significant challenges:
Insufficient Protection: Precision braking components are prone to surface scratches and internal misalignment due to inadequate shock absorption from wooden or basic plastic packaging, resulting in a transportation damage rate of up to 7%.
Poor Space Utilization: Irregular loading in traditional containers leads to low space efficiency and increased logistics costs.
Time-Consuming Manual Handling: Manual counting is labor-intensive, error-prone, and hampers supply chain efficiency.
Data Disconnect: Lack of real-time monitoring disrupts supply chain coordination.
Innovative Solution: Injection-Molded Inner Lining Three-Tier Rack
To address these challenges, we developed a three-tier transport rack with an injection-molded inner lining, adopting a "modular protection + standardized loading" philosophy. This solution enhances efficiency, security, and digital integration for Audi A5L calipers.
Concept Development
By analyzing the caliper's "horseshoe" structure and logistics workflow, we identified the need for precise positioning and batch-specific storage. This led to the development of a modular design using injection-molded inner linings and a three-tier vertical storage system.
Design Breakthroughs
Precision Modeling:
3D scanning captured the caliper's exact contours.
Finite element analysis simulated transportation vibrations to design an inner lining with "concave slots + elastic buffer walls," ensuring a tolerance of <0.5mm per slot.
Three-Tier Layout Design:
A staggered "pin"-shaped stacking optimizes vertical space while preventing pressure concentration.
Each tier holds 14 calipers, with RFID tag slots pre-integrated for digital tracking.
Manufacturing Execution
Injection Molding Process:
Materials: Food-grade HDPE with impact modifiers.
Process: Injection molding at 200°C, achieving Shore D65 hardness after cooling.
Precision: ±0.1mm tolerance for critical components.
Frame Construction:
6061-T6 aluminum alloy frame CNC-machined with ±0.1mm precision.
Treated with anodized anti-corrosion coating.
Quality Assurance:
Vision inspection systems ensure 100% secure locking between the inner lining and frame.
Validation & Optimization
Vibration Testing: Simulated truck transport conditions (frequency: 2-200Hz, acceleration: 3g) resulted in caliper displacement <1mm.
Drop Testing: A 1.2-meter free fall caused 30% compression of the buffer layer, with zero visible caliper damage.
Durability Testing: After 50 loading/unloading cycles, slot wear was <0.2mm, and frame deformation was <0.3mm.
Value Delivered
Enhanced Protection: The transportation damage rate plummeted from 7% to 0.3%, reducing per-caliper insurance costs by 60%.
Operational Efficiency: Loading speed increased 4x (manual: 10 calipers/10 minutes → robotic arm: 14 calipers/2 minutes).
Warehouse Storage Density: Increased by 35% (from 80 units/m³ to 108 units/m³).
Digital Integration: RFID integration with OEM MES systems enabled real-time logistics tracking and inventory alerts, reducing 4S dealership stockout complaints by 85% in pilot regions.
Industry Insights
This case study demonstrates how three-dimensional innovation—material (injection-molded lining), structural (three-tier modular design), and digital (RFID tracking)—can transform transport racks into strategic assets. By adopting end-to-end lean design, supply chain efficiency is redefined, driving optimization of OEM production schedules.
