Adjustable Post Support with Dual Rotation Stages
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Solution Overview
Problem
Existing adjustable post supports are cumbersome, unstable, expensive, and complicated to use, making it difficult to achieve verticality of posts in various mounting scenarios, such as ground-dug holes, preexisting structures, and post mounts driven into the ground.
Innovation Solution
An adjustable post support design featuring upper and lower adjustment plates that can be rotated relative to each other and to the post receptacle and mount, allowing for easy adjustment of the post's angular orientation relative to the horizon, with the ability to achieve any of thousands of possible angles, and can be fabricated from materials like metal, plastic, or carbon fiber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ball-and-socket connections are used to allow post angle adjustment, then post verticality can be achieved, but the device becomes cumbersome, unstable, expensive, and complicated to use
Solution Approach 1:
The adjustment mechanism is divided into two independent rotation stages: the first rotation stage adjusts the angle between the mount and intermediate member, while the second rotation stage adjusts the angle between the intermediate member and post receptacle. This segmentation allows each stage to be simple and stable while achieving comprehensive angular adjustability when combined.
Solution Approach 2:
The intermediate member serves multiple functions: it acts as a connection element between the mount and post receptacle, provides the first rotation stage for angular adjustment, and serves as a stable structural component. This multi-functionality reduces the need for additional complex components while maintaining adjustment capability.
2Adaptability or versatility
If existing adjustable post supports are used, then post verticality can be achieved, but they are expensive to manufacture
Solution Approach 1:
Dividing the adjustment mechanism into two simple rotation stages with basic rotational joints reduces manufacturing complexity compared to complex ball-and-socket connections. Each stage can be manufactured independently using simpler processes, lowering overall production costs.
Solution Approach 2:
The design uses simple, replaceable rotation stages that can be manufactured economically. The modular structure allows for cost-effective production and potential replacement of individual components without requiring expensive precision-machined integrated assemblies.
3Adaptability or versatility
If existing adjustable post supports are used, then post verticality can be achieved, but they are cumbersome and complicated to use
Solution Approach 1:
The two-stage rotation system allows users to make adjustments in discrete, manageable steps rather than dealing with a complex multi-degree-of-freedom mechanism. Each rotation stage can be independently adjusted, making the operation intuitive and easier to control.
Solution Approach 2:
The rotation stages provide dynamic adjustability during installation, allowing the post to be positioned at various angles. Once the desired vertical position is achieved, the structure becomes stable and rigid, combining ease of adjustment with operational stability.
4Ease of operation
If post mounts are driven into the ground, then installation convenience is improved, but it is difficult to insure perpendicular orientation and the mount can be deflected by underground obstacles
Solution Approach 1:
The first rotation stage allows the mount to be driven into the ground at any orientation without concern for precision, as the angular adjustment will be made later through rotation. This preliminary installation followed by adjustment approach separates the driving operation from the orientation operation.
Solution Approach 2:
The rotation stages provide dynamic adjustment capability after the mount is installed, allowing correction of any orientation errors. The system transitions from a static fixed-orientation mount to a dynamically adjustable configuration, enabling precise vertical alignment regardless of initial installation accuracy.
Data Source
AI summary
An adjustable post support includes a post receptacle with a first longitudinal axis; a mount with a second longitudinal axis; and upper and lower adjustment plates disposed therebetween. The upper adjustment plate resides closer to the receptacle, rotates about the first longitudinal axis, and has a first surface above an opposing second surface. The first surface remains normal to the first longitudinal axis when rotated. The second surface resides at an angle to the first surface. The lower adjustment plate rotates about the second longitudinal axis and has a third surface above an opposing fourth surface. The fourth surface remains normal to the second longitudinal axis when rotated. The third surface resides at an angle to the fourth surface. The second surface is disposed against the third surface.