Integrated Treadmill Base With Injection-Molded, Weld-Free Assembly
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Solution Overview
Problem
Existing treadmill bases require complex welding processes, skilled labor, and high production costs, hindering automation and standardization.
Innovation Solution
A treadmill with an integrated base formed by a horizontally arranged support rod wrapped with a metal member, using injection molding and robotic assembly to simplify manufacturing and reduce environmental pollution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If welding technology is used to connect metal crossbeams and longitudinal beams, then the base structure can be assembled, but the assembly process becomes complex and requires skilled welding workers
Solution Approach 1:
The patent merges multiple separate metal components (crossbeams and longitudinal beams) into a single integrated base structure. This integration eliminates the need for welding connections between multiple parts, simplifying the assembly process to a single-piece installation while maintaining structural integrity.
Solution Approach 2:
The patent extracts the welding operation from the assembly process by designing a base that does not require welding. The integrated base structure is designed to be installed as a complete unit, removing the complex welding step and the associated skill requirements from the manufacturing process.
2Extent of automation
If welding technology is used to connect base components, then the base can be assembled, but differences in welding levels hinder automation and standardization
Solution Approach 1:
By combining multiple weldable components into one integrated base structure, the patent eliminates the welding process entirely. This enables complete automation in base installation since the integrated base can be positioned and secured using standardized mechanical methods, achieving both automation and standardization simultaneously.
3Ease of manufacture
If multiple metal components are connected by welding, then the base structure can be formed, but production cost increases
Solution Approach 1:
The patent combines multiple metal components into a single integrated base structure manufactured as one piece. This eliminates welding costs, reduces material waste from cutting and fitting separate components, and simplifies quality control, thereby reducing overall manufacturing cost while maintaining or improving structural strength through the integrated design.
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 integrated base structure allows for simple assembly, reduces manufacturing costs, and eliminates the need for skilled labor while maintaining structural integrity.
Implementation Method 1
automatically lowering the metal member from the fixture by a robotic arm and placing it into a base mold; closing the base mold, injecting liquid plastic material into the mold, maintaining pressure after injection is completed
Implementation Method 2
after the pressure is maintained, adding materials and cooling down; after cooling to room temperature, opening the base mold and demolding the base
Data Source
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AI summary
The present disclosure provides a treadmill with an integrated base and a manufacturing method for the integrated base, the treadmill includes the integrated base, a running board, a running belt, an electric motor, an electric control, and a drum. The integrated base includes a horizontally and longitudinally arranged support rod that is integrally formed, the support rod is enclosed to form a rectangular base. The horizontally and/or longitudinally arranged support rod is wrapped with a metal member, the integrated base is provided with an installation part for the running board, running belt, electric motor, electric control, and drum. This setting overcomes a shortcoming of a complex structure of the existing treadmill base, eliminates a high production cost of welding assembly, reduces environmental pollution, and requires lower personnel skills. It has the advantages of simple assembly and low manufacturing cost.