Keder Rail Tensioning for Faster Fabric Panel Assembly
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Solution Overview
Problem
The assembly of fabric-covered buildings is labor-intensive and time-consuming due to the difficulty in securing multiple fabric panels to building frames in a taut position, often requiring workers to constantly stretch and reposition panels across the frame.
Innovation Solution
A fabric panel attaching system that includes a keder rail with a mounting arm and support structure, where the mounting arm is initially positioned apart from the support, allowing for easy installation of fabric panels in a slack state, and then tensioned using a bolt and nut system to secure the panels tightly against the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fabric panels are secured to building frames in a taut position, then the quality of the final product is improved, but the assembly process becomes labor-intensive and time-consuming
Solution Approach 1:
The mounting arm is pre-positioned in a retracted state that allows fabric panels to be installed in a slack state without requiring workers to manually stretch and tension the fabric during installation. The tensioning action is deferred to a later stage when the mounting arm is extended, performing the tensioning function in advance of the final secured position.
Solution Approach 2:
The mounting arm transitions from a retracted position during installation to an extended position during tensioning, creating a dynamic system that adapts its configuration based on the operational stage. This dynamic adjustment allows the same structure to facilitate both easy installation and proper tensioning without requiring separate fixed structures for each function.
2Manufacturing precision
If multiple fabric panels are secured individually, then the fabric cover is properly tensioned, but the labor cost and time required increase significantly
Solution Approach 1:
The system allows all fabric panels to be preliminarily installed in a slack state without tensioning, completing the installation phase quickly. The tensioning action is then performed uniformly across all panels by extending the mounting arm, eliminating the need for individual manual tensioning of each panel and significantly reducing total assembly time.
3Ease of operation
If mounting tracks are positioned closer than final installed position, then panels can be pulled through easily, but additional labor is required to reposition tracks and tension fabric
Solution Approach 1:
The mounting arm is designed to be pre-positioned in a retracted state during installation, creating sufficient clearance for fabric panels to be installed without requiring temporary track repositioning. This preliminary configuration of the mounting arm eliminates the need for subsequent track repositioning operations while still allowing proper tensioning when the arm is extended to its final position.
Data Source
AI summary
A fabric panel attaching system and methods of assembly and use are presented for attaching fabric panels to structural elements, such as building frames. In various embodiments, the fabric panel attachment system includes a keder rail fastened to support bar, which is attached to a structural profile, such as a building frame member. In some embodiments, the keder rail is fastened to a support bar with bolt and nut. One or more fabric panels are installed within channels of the keder rail. An alignment element may be used with a fastener to assist in aligning abutting sections of keder rail. In various embodiments, the fabric panel attachment system is secured to flat or curvilinear faces of the structural elements. In some embodiments, the fabric panel attachment system may secure directly to the structural element and not a support bar.