Mercedes-Benz Automobile Shock Absorber Rack Automobile Shock Absorber Rack

Mercedes-Benz Rear Shock Absorber Dedicated Rack Case Study—Modular Packaging Innovation in the Industry 4.0 Era

I. Project Background and Challenges

Part Specifications: Iron outer panel (178×630×75mm), transported across three stages: stamping shop → body shop → assembly shop, covering a 2,000-meter complex route (combining conveyors, trailers, and forklifts).

Critical Pain Points:

Misalignment Issues: Traditional racks caused >5% part misalignment during robotic arm handling due to positioning gaps.

Inadequate Protection: 3% surface scratches on iron parts compromised assembly line efficiency.

Ergonomic Risks: Blind zones in manual operations (490-900mm height range) increased injury risks.

II. Innovative Design Solutions

Submillimeter Precision Positioning

Tri-Coordinate Error-Proofing: Polyurethane positioning modules (±0.2mm accuracy) with 2mm lateral constraints at points A/B/C.

Dynamic Stability: Q235 steel frame (760×1150×760mm) with EVA strips, validated to withstand 3g acceleration vibrations in simulations.

Multi-Layer Protection System

Four Protective Layers:

▶ Dustproof Top Cover: Soft glass + mesh curtain (IP54 rating).

▶ Interlayer Buffering: Molded polyurethane profiles (Shore 65A hardness).

▶ Pneumatic Assistance: Dual gas springs enable stepless height adjustment, reducing manual effort by 30%.

▶ Safety Redundancy: Right-side self-locking mechanism prevents accidental release.

Smart Loading Architecture

4×6 Vertical Storage: 24 parts/rack (300% higher density than single-layer solutions).

Robotic Compatibility: Optimized for robotic arm trajectories in stamping/body shops (±0.5mm repeat positioning accuracy).

III. Key Performance Metrics

Metric Legacy Rack Innovative Rack Improvement

Part Misalignment Rate 5% 0.3% ↓94%

Surface Scratch Rate 3% 0.5% ↓83%

Loading Capacity per Rack 6 parts/layer 24 parts/rack ↑300%

Handling Efficiency 8 min/rack 2 min/rack ↑300%

IV. Supply Chain Value Transformation

Quality Assurance: Assembly line first-pass yield increased by 2.8%, reducing rework costs by CNY 1.2 million/year.

Logistics Optimization: Transport frequency decreased by 40%, saving CNY 350,000/year in forklift fuel costs.

Ergonomic Safety: Operational heights aligned with 90% of ergonomic standards, lowering workplace injuries by 65%.

V. Industry Insights

Modular Design Framework: Q235 steel + polyurethane modules reduce redesign cycles to 72 hours.

Error-Proofing Synergy: Combines mechanical constraints (rigid) and pneumatic buffering (flexible).

Digital Twin Validation: Transport path simulations achieved 100% first-time design success.

This solution is included in Mercedes-Benz's 2025 Advanced Manufacturing Packaging Standards Whitepaper, projected to reduce automotive stamping part logistics costs by 18-22% industry-wide.

From Functional Containers to Value Catalysts

By integrating physical protection with production workflows, logistics dynamics, and human-machine interfaces, this rack redefines packaging as an organic component of smart manufacturing systems. Mercedes-Benz's case offers a replicable Industry 4.0 blueprint for discrete manufacturing scenarios.