Design and Development of a Cross-Compatible Load Carriage System for Professional Forestry Equipment : An Investigation into Structural Integrity and Design Trade-offs in Professional Forestry Equipment

Sammanfattning

This master´s thesis explores the design and development of a Cross-Compatible Load Carrying System (CCS) intended for professional forestry and wildfire management in extreme terrain. As global wildfires increase in frequency and duration, there is a growing need for equipment that allows users to transport heavy chainsaws and accessories over long distances where vehicle access is not possible. A preliminary market review revealed a gap in existing solutions, which often lack the structural stability and ergonomic refinement required for heavy, professional equipment. The project aimed to develop a cross-compatible system based on the Tatonka Lastenkraxe backpack frame. The development process followed a structured product design methodology, beginning with stakeholder interviews and market analysis to establish mechanical and ergonomic requirements. Technical realization involved reverse engineering the backpack frame in CAD and performing simulations, including Finite Element Analysis (FEA) and plastic injection molding simulations, to optimize structural integrity and manufacturability. Results from the simulation and prototyping led to a 14% weight reduction in the base plate and a 12% reduction in the guide-bar clip through strategic material placement. Physical validation of the prototype confirmed that the system effectively secures the center of mass (CoM) close to the user´s spine, reducing lateral instability and physical strain compared to carrying equipment by hand. The final concept provides a modular platform that accommodates various chainsaw sizes (50cc to 90cc) and two different fuel types (petrol and electric), ensuring safe and efficient transportation in demanding environments. This research contributes to the field by offering a technical foundation for future universal carrying systems, enhancing the safety and operational mobility of forestry workers and emergency responders.