LED Display Tile Alignment via Segmented Structural Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display systems face challenges in achieving simultaneous strength and positional accuracy, as large structural components required for support often compromise alignment precision, leading to noticeable gaps and luminance differences between tiles, especially in outdoor applications where wind loads are a factor.
Innovation Solution
The display system separates alignment and structural support functions, using accurately manufactured tiles with minimal strength requirements and secondary structural support to provide rigidity, allowing for precise alignment through clips and attachment members that nullify tolerance differences, enabling high accuracy and cohesive display appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large structural components are used to provide strength and rigidity, then the display system can withstand wind loads and support large areas, but the alignment precision deteriorates due to manufacturing tolerances and cumulative errors
Solution Approach 1:
The system divides the support structure into modular tiles that can be manufactured with high precision independently. Each tile is a discrete unit with standardized connection interfaces, allowing the overall large structure to be assembled from many small, precisely manufactured components. This segmentation eliminates the need to manufacture one large complex structure, thereby maintaining alignment precision while achieving the required structural strength through the collective assembly.
Solution Approach 2:
Connection elements such as clips, tabs, and receptacles serve as intermediaries between tiles. These intermediaries are designed to accommodate and nullify tolerance differences that arise during assembly. The connection elements provide the necessary mechanical coupling for structural strength while incorporating compliance features that maintain precise alignment despite manufacturing variations in the tile components themselves.
2Ease of operation
If tiles are designed for easy manual handling and installation, then the display system becomes easier to install and reconfigure, but the alignment accuracy deteriorates due to cumulative positioning errors
Solution Approach 1:
Alignment features such as guide rails, positioning pins, and keyed interfaces are pre-built into the tile design during manufacturing. These preliminary alignment mechanisms guide the tiles into correct positions automatically during the installation process, eliminating the need for complex manual alignment procedures. Installers simply need to connect the tiles using the pre-designed interfaces, which self-align the pixels across tile boundaries while maintaining ease of installation.
3Adaptability or versatility
If the display system is designed to be easily removable and reconfigurable, then the system becomes more adaptable to different events and configurations, but the structural strength deteriorates due to removable connections
Solution Approach 1:
The connection system is designed with dynamic characteristics, allowing it to transition between locked and unlocked states. The clips and receptacles can be securely engaged to provide structural strength during operation, yet can be easily disengaged when reconfiguration is needed. This dynamic connection mechanism maintains full structural integrity during normal use while enabling rapid reconfiguration when required, achieving both strength and adaptability.
Data Source
AI summary
A display system, a method of constructing a display system, and a method of displaying an image are described. In one embodiment, a display system includes a support structure having a plurality of attachment members and a plurality of tiles. Each of the plurality of tiles is attached to a corresponding attachment member of the plurality of attachment members. The support structure is configured to structurally support each of the plurality of tiles, and at least one of the plurality of tiles includes at least one connection configured to removably connect and align the at least one of the plurality of tiles with another one of the plurality of tiles.