Modular Profile Bar and Connector Layout for Stable Custom Workstations
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Solution Overview
Problem
Existing modular kits for manufacturing customized carts, workstations, and storage units often require numerous connecting elements and lack stability, leading to inefficient and costly solutions that do not optimize operator workflows in lean production environments.
Innovation Solution
A modular kit featuring profiled bars with eight contoured longitudinal crests and connectors with jaws that clamp in eight radial directions, allowing for versatile and stable assembly of structures using a minimal number of elements, including a hollow duct for accessory anchoring and expansion plugs for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing modular kits use multiple connecting elements to achieve versatility, then adaptability is improved, but device complexity increases
Solution Approach 1:
The connector is designed with a universal structure that can connect to bars in multiple orientations and positions. The jaws can clamp onto bars at any point along their length, and the connector can be oriented in different directions, eliminating the need for multiple specialized connecting elements while maintaining high versatility
Solution Approach 2:
The connector is divided into functional segments: jaws for clamping the bar, a body for structural support, and connection points for attaching to other bars. This segmentation allows each part to perform its specific function efficiently while the overall design remains simple and uses minimal components
2Ease of manufacture
If existing modular kits use standard connectors to simplify assembly, then ease of manufacture is improved, but stability deteriorates due to oscillations and bending
Solution Approach 1:
The connector incorporates curved surfaces and rounded joints that distribute mechanical stresses more evenly throughout the structure. The curved geometry of the jaws and connection points reduces stress concentration points that would otherwise lead to bending and oscillations, while maintaining ease of assembly
Solution Approach 2:
The connector design includes built-in stress-absorbing features such as flexible joints and cushioning elements that preemptively reduce the impact of dynamic loads and vibrations before they can cause instability or damage to the modular structure
3Stability of the object's composition
If existing modular kits use numerous connecting elements to achieve stability, then stability is improved, but cost increases
Solution Approach 1:
Multiple functions that would traditionally require separate components are merged into a single connector design. The connector simultaneously provides clamping, positioning, structural support, and stress distribution functions, reducing the total number of elements needed while maintaining or improving stability
Solution Approach 2:
The universal connector can perform multiple roles in different positions and orientations within the modular structure, replacing what would otherwise require several different specialized connectors. This multi-functionality reduces component count and material costs while maintaining structural integrity
Data Source
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AI summary
A modular kit for the customized manufacture of carts, workstations, storage units and similar structures, which comprises at least one profiled bar (2A, 2B) and at least one connector (3a, 3b), which is provided with respective jaws (4) for clamping the bar (2A, 2B). The bar (2A, 2B) has at least eight contoured longitudinal crests (5), which are substantially arranged at equal distances from each other along the lateral surface of the bar (2A, 2B); the crests (5) constitute abutment shoulders for the jaws (4), which in turn are shaped complementary to the crests (5), for the clamping of the bar (2A, 2B) by the connector (3a, 3b), according to at least eight respective different radial directions. Moreover, the bar (2A, 2B) has a hollow duct (6), which is arranged coaxially inside it, and at least four longitudinal slots (7), arranged at equal distances from each other along its lateral surface and delimited by respective pairs of crests (5). Each slot (7) forms a seat for coupling to shelves, panels, accessories and tools of various types to be anchored to the bar (2A, 2B).