Adjustable Torque Shaft Assembly for Lift Door Counterbalance
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Solution Overview
Problem
Conventional lift systems require fixed-length torque shafts, leading to inefficient storage and high shipping costs due to non-standard container sizes, and necessitate consumer-cutting, which is costly and error-prone.
Innovation Solution
An adjustable length torque shaft system comprising two outer torque shafts and a middle torque shaft, allowing customizable length adjustment without cutting, shipped in component parts to reduce shipping costs and simplify installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed-length torque shafts are used to match specific door widths, then the door can be supported evenly on both sides, but storage space increases and shipping costs rise due to nonstandard container sizes
Solution Approach 1:
The torque shaft is divided into multiple modular segments that can be assembled in different combinations. Each segment is a standardized component that can be joined together to create torque shafts of various lengths, allowing the same set of segments to serve multiple door width requirements without requiring separate storage for each length.
Solution Approach 2:
The system transitions from static fixed-length torque shafts to a dynamic, reconfigurable assembly. The modular segments can be quickly assembled and disassembled to adapt to different installation requirements, making the system flexible rather than rigid, thereby reducing the need to stock multiple fixed configurations.
2Manufacturing precision
If fixed-length torque shafts are manufactured for each door size, then accurate fitting is achieved, but manufacturing complexity and inventory management difficulty increase
Solution Approach 1:
A single set of standardized torque shaft segments serves multiple functions across different door sizes and applications. The same universal segments can be combined in various configurations to create torque shafts of different lengths, eliminating the need to manufacture and maintain separate inventory for each door size specification.
Solution Approach 2:
Instead of changing the physical dimensions of entire torque shafts for different applications, the system changes the configurable parameter of total length by assembling different numbers and combinations of standardized segments. This allows precise length adjustment while maintaining uniform segment specifications throughout the inventory.
3Adaptability or versatility
If consumers cut torque shafts to fit their doors, then customization is achieved, but installation cost and error risk increase due to required expertise and equipment
Solution Approach 1:
The torque shaft is pre-segmented into standardized modular sections that can be easily assembled or disassembled without requiring cutting tools or specialized equipment. Consumers can simply connect or disconnect segments to achieve the required length, eliminating the need for expensive cutting equipment and expert intervention.
Solution Approach 2:
Instead of requiring the consumer to modify a single long shaft by cutting it down, the system inverts the approach by providing pre-divided segments that are assembled to the correct length. This reverses the traditional customization process from subtractive (cutting) to additive (assembling), making it safer and easier for end-users.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adjustable length torque shaft system reduces storage needs, lowers shipping costs, simplifies installation by eliminating the need for cutting, and ensures accurate fitting for various door sizes, enhancing usability and safety.
Implementation Method 1
two torsion springs disposed around the adjustable length shaft and operably connected to the adjustable length torque shaft, wherein the two torsion springs exert a torsional force on the adjustable length torque shaft to counterbalance at least a portion of the weight of the lift door
Data Source
AI summary
An adjustable length counterbalance mechanism for lift doors, frequently used for cargo trailers and garages. The adjustable length torque shaft of the counterbalance mechanism is able to accommodate many different lift door widths and is simpler to install than a fixed length torque shaft. In embodiments, the adjustable torque shaft is comprised of two outer torque shafts, each with a torsion spring and cable drum and a middle torque shaft that can be assembled together. The middle torque shaft can be inserted into each of the outer torque shafts to a selected depth to determine the length of the adjustable torque shaft.