Fence Panel Frame Fins for Tolerance-Tolerant Resistance Welding
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Solution Overview
Problem
The manufacture of prefabricated fencing panels faces challenges due to manufacturing tolerances, dimensional changes during fabrication and handling, and welding irregularities, leading to dimension mismatches between the frame and the barrier component, which complicates reliable attachment and results in low production efficiency, poor quality, and high rejection rates.
Innovation Solution
Incorporating inboard fins on the frame members that extend sufficiently to accommodate manufacturing tolerances, dimensional changes, and welding irregularities, allowing for reliable resistance welding of the barrier component to the fins, thereby ensuring efficient production, aesthetically pleasing panels, reduced rejection rates, and automated fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the barrier component and frame are sized to allow reliable connection, then manufacturing precision requirements increase, but production efficiency decreases and costs increase
Solution Approach 1:
The patent changes the dimensional parameters of the frame by adding fins that extend beyond the nominal frame width. This parameter change creates a larger attachment surface area that can accommodate dimensional variations in the barrier component, allowing reliable connections without requiring tight manufacturing tolerances on the main frame and barrier components, thus maintaining production efficiency
Solution Approach 2:
The frame is segmented into the main frame structure and separate fins that protrude from it. This segmentation allows the fins to serve as dedicated attachment features that can independently accommodate dimensional variations, while the main frame and barrier component can be manufactured with standard tolerances using efficient processes
2Manufacturing precision
If manufacturing tolerances are tightened to reduce dimension mismatches, then attachment quality improves, but production costs increase and automation becomes difficult
Solution Approach 1:
Instead of tightening tolerances on the main components, the patent changes the geometric parameters by adding protruding fins to the frame. This allows the use of standard manufacturing tolerances while achieving reliable attachment, simplifying the manufacturing process and enabling automation
Solution Approach 2:
The fins act as an intermediary element between the frame and the barrier component. They provide a intermediate attachment surface that absorbs dimensional variations, allowing both the frame and barrier component to be manufactured with standard tolerances using simple, automated processes
3Strength
If the barrier component is made rigid for structural strength, then welding precision requirements increase, but production efficiency decreases
Solution Approach 1:
The patent adds a dimensional feature (fins) to the frame that protrudes outward, creating an extended attachment surface. This dimensional addition provides a larger welding area that can accommodate variations in the rigid barrier component's dimensions, allowing fast automated welding without compromising structural strength
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 solution enables reliable attachment of the barrier component to the frame, improving production efficiency, reducing rejection rates, and allowing for automated fabrication while maintaining aesthetic quality.
Implementation Method 1
A metal barrier component may be joined to a metal frame by resistance welding between the barrier component and inboard fins extending from the beam portions of the frame rails
Data Source
AI summary
A fence panel comprises a first frame rail that includes a first beam portion and a first fin that is adjacent to the first beam portion, and a barrier component attached to the first fin. A resistance weldment may reside at the attachment between the barrier component and the first fin. The first fin may be integral with the first beam portion. The first frame rail and the first fin may comprise a single roll form or a single extrusion.