Modular LED Wall Truck Assembly for Fast Precision Alignment
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Solution Overview
Problem
The installation and reconfiguration of LED screens for filming backdrops is time-consuming and costly due to their bulkiness, limiting mobility and requiring frequent realignment for precise positioning, especially when moving between different studio spaces or over uneven surfaces.
Innovation Solution
A modular LED wall system with a truck assembly featuring omnidirectional wheels, ball bearings, and adjustable actuators that allow precise leveling and alignment of LED panels, enabling seamless integration and movement across various surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If LED screens are arranged as a wall for filming backdrops, then the display quality and backdrop appearance are improved, but the installation time and reconfiguration cost increase due to bulkiness and limited mobility
Solution Approach 1:
The LED wall is divided into multiple modular panels that can be independently handled, transported, and assembled. Each panel is a self-contained unit with standardized interfaces, allowing rapid reconfiguration without requiring complete disassembly and reinstallation of the entire wall structure.
Solution Approach 2:
The system incorporates movable support structures with adjustment mechanisms that enable dynamic repositioning of LED panels. The support system includes height-adjustable legs and positioning mechanisms that allow quick adaptation to different installation locations and configurations.
2Adaptability or versatility
If LED screens are moved to different studio spaces or positions, then versatility and adaptability are improved, but realignment and releveling are required due to stage floor variations
Solution Approach 1:
The support structures incorporate adjustable parameters including height, angle, and position. Each LED panel support can be independently adjusted in multiple degrees of freedom to compensate for floor irregularities and achieve precise alignment with adjacent panels, maintaining display continuity across different installation locations.
Solution Approach 2:
Adjustable support structures act as intermediaries between the LED panels and the stage floor. These supports include leveling mechanisms and position-adjustment features that isolate the panels from floor variations, ensuring precise alignment regardless of the underlying surface irregularities.
3Adaptability or versatility
If LED screens are frequently reconfigured for different scenes, then scene adaptability is improved, but hardware cost and installation complexity increase
Solution Approach 1:
The LED wall system is segmented into standardized modular panels with uniform connection interfaces. This segmentation allows panels to be easily assembled and disassembled in various configurations for different scenes, reducing installation complexity despite increased reconfiguration frequency.
Solution Approach 2:
The modular panels and support structures are designed with universal interfaces and standardized dimensions that enable the same hardware components to be used across multiple scenes and configurations. This universality reduces the need for specialized equipment for different scenes, lowering overall hardware costs.
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
Facilitates rapid, cost-effective reconfiguration and alignment of LED panels with pixel-level precision, enhancing mobility and reducing installation time and damage risk during repositioning.
Implementation Method 1
Each of the first actuators may comprise a bladder configured to lift the support assembly upon expanding
Implementation Method 2
a plurality of ball bearings arranged between the first and second support bases to allow relative movement of the first and second support bases in a plane parallel to the stage surface
Implementation Method 3
a plurality of omnidirectional wheels (e.g., mecanum wheels, etc.) arranged to enable omnidirectional movement of the second support base along the stage surface
Data Source
AI summary
A wall module of a modular LED wall includes an array of LED panels and a truck for supporting the array of LED panels and providing mobility thereto relative to a stage surface. The truck may include a support assembly including a first support base fixed to the array of LED panels, a second support base engageable with the first, and a plurality of ball bearings arranged between the first and second support bases to allow relative movement of the first and second support bases in a plane parallel to the stage surface, a plurality of omnidirectional wheels arranged to enable omnidirectional movement of the second support base along the stage surface, and one or more actuators operable to adjust a height of the support assembly at a plurality of positions on the support assembly to enable leveling of the support assembly relative to the stage surface.