Modular LED Video Wall Frame with Articulated Support Beams
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Solution Overview
Problem
Existing modular frames for supporting large LED panels face challenges in maintaining precise alignment and structural integrity due to deflection under heavy loads, requiring cumbersome adjustment methods and inadequate cable management, which complicates the assembly and maintenance of video walls.
Innovation Solution
A modular frame system comprising articulated secondary beams centered over the center of mass of LED panels, hollow tubular primary beams for compact space, and a stabilization mechanism with angled guy wires and a calibration/cleaning system using movable trolleys and actuators to ensure alignment and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a perfectly straight structural beam is used to suspend LED panels, then alignment precision is improved, but beam deflection under heavy load increases
Solution Approach 1:
The patent divides the single long beam into multiple shorter beam segments (first beam segment, second beam segment, etc.) connected by adjustable connection mechanisms. This segmentation reduces the span length of each individual beam, thereby reducing deflection under load while maintaining overall alignment precision through the adjustable connections between segments.
Solution Approach 2:
The patent employs adjustable connection mechanisms that allow dynamic adjustment of beam segments during and after assembly. This enables the system to adapt to load conditions and maintain alignment precision even when individual segments experience deflection, as the connections can be adjusted to compensate for variations.
2Manufacturing precision
If turnbuckles and winches are used to align frame members, then vertical alignment is improved, but assembly complexity increases
Solution Approach 1:
The connection mechanisms are divided into modular components that can be independently adjusted. Each connection point between beam segments can be adjusted separately, simplifying the alignment process compared to using turnbuckles and winches on a single continuous beam structure.
Solution Approach 2:
The adjustable connection mechanisms are designed to be self-aligning to a degree, reducing the need for complex external alignment equipment. The mechanisms allow operators to make direct adjustments without requiring additional tools like turnbuckles and winches, thereby reducing assembly complexity while maintaining alignment precision.
3Adaptability or versatility
If cables are routed behind the display, then power and data connections are established, but trip hazards are created
Solution Approach 1:
The patent routes cables through the vertical dimension by providing cable access through the support structure itself (through openings in the beam segments or support columns). This elevates the cables from the horizontal plane behind the display to a vertical pathway integrated into the support structure, eliminating trip hazards while maintaining connectivity.
4Adaptability or versatility
If modular frames are used to support LED panels, then assembly flexibility is improved, but structural integrity under heavy load deteriorates
Solution Approach 1:
The modular frame is segmented into multiple beam segments and support columns that can be independently adjusted. This segmentation allows the structure to be configured in different modular arrangements for assembly flexibility, while the multiple connection points and adjustable mechanisms distribute loads effectively to maintain structural integrity under heavy LED panel loads.
Solution Approach 2:
The adjustable connection mechanisms in the modular frame allow for dynamic tuning of the structure after assembly. This enables optimization of load distribution and structural integrity for specific installations while maintaining the inherent flexibility of modular design. The connections can be adjusted to account for variations in panel weight and configuration.
Data Source
AI summary
A modular frame for supporting one or more LED panels to form a video wall, a leveling system for the video wall, and a calibration and/or cleaning system for the LED panels of the video wall. The modular frame is a framework comprising at least two support columns, a primary support beam and at least one secondary support beam wherein the at least two support columns are spaced apart with the primary support beam extending substantially laterally thereacross, and a plurality of stiffening elements. The at least one secondary support beam is an articulated support beam for suspending a column of one or more LED panels therefrom and wherein the articulation point of each of the at least one secondary support beams as connected to the primary support beam is substantially centered over the center of mass of the one or more LED panels suspended therefrom. A plurality of modular frames can be secured together to form the video wall of a selected width and height with LED panels suspended in one or more rows and one or more columns.