Modular Electronic Display Assembly Using Transport Jig
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Solution Overview
Problem
Current large-scale electronic displays are cumbersome, costly, and difficult to maintain due to their bulky design, lack of modularity, and requirement for specialized equipment for installation and maintenance, which limits scalability and increases the overall cost of ownership.
Innovation Solution
A modular design for large-scale electronic displays that allows for easy access to components, simplified installation, and maintenance by using a transport jig system and a front-accessible glass door, enabling quick assembly, disassembly, and replacement of parts without the need for expensive lifting equipment or multiple site visits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional large advertising screens are manufactured to suit specific projects with bespoke designs, then the display can meet specific client requirements, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The display system is divided into separate modular components: a standardized housing and interchangeable display cassettes. Each cassette contains specific components (LCD panel, power supply, cooling fan, PC board) that can be independently selected and replaced. This segmentation allows customization through component selection rather than bespoke design, reducing manufacturing complexity while maintaining adaptability.
Solution Approach 2:
The standardized housing design serves multiple functions and can accommodate different display cassettes for various applications. The same housing structure is used across different projects, with customization achieved through cassette configuration rather than housing redesign. This universal approach reduces design complexity while meeting diverse client requirements.
2Productivity
If fully integrated LCD cassettes are used with mass produced housings, then manufacturing efficiency improves, but the weight and complexity of lifting and installation equipment increases
Solution Approach 1:
The display system separates the housing from the cassette components, allowing the cassette to be a manageable size for handling. The cassette contains only essential components (LCD panel, power supply, cooling fan, PC board) rather than being overly integrated, optimizing the weight-for-function ratio and improving manufacturing efficiency without excessive weight.
3Device complexity
If screens are designed without provision for component swapping, then the initial design is simpler, but maintenance time and cost increase due to complete display replacement requirements
Solution Approach 1:
The display is segmented into a housing and removable cassette, with the cassette further divided into replaceable components (power supply, cooling fan, PC board, LCD panel). This modular structure enables individual component replacement without replacing the entire display, simplifying maintenance while the standardized housing keeps initial design relatively simple.
Solution Approach 2:
The housing is pre-designed with access points, removal mechanisms, and mounting structures that anticipate future maintenance needs. These features are built into the initial design to facilitate easy component swapping during maintenance, rather than requiring complex disassembly procedures.
4Volume of moving object
If control electronics are integrated in the base unit, then the display structure is more compact, but access to electronics for maintenance becomes difficult when screens are positioned close to buildings
Solution Approach 1:
The control electronics are segmented from the base unit and integrated into the removable cassette. This allows the cassette to be accessed and serviced independently by removing it from the housing, providing maintenance access without requiring access to the base unit or moving the entire display structure.
Solution Approach 2:
The housing is pre-designed with front access points and removal mechanisms that enable technicians to access the cassette and its electronics from the front of the display. This preliminary design feature ensures maintainability even when the display is positioned against walls or in hard-to-reach locations.
5Reliability
If screens are made extremely heavy and bulky to withstand outdoor conditions, then durability improves, but storage, transport and installation become difficult and expensive
Solution Approach 1:
The display system is segmented into a durable housing and a separate cassette that can be handled more easily. The housing provides the necessary structural strength for outdoor conditions, while the cassette contains the electronic components in a lighter, more manageable form factor, reducing transport and installation difficulties.
Solution Approach 2:
The cassette is designed to be dynamically removable and replaceable, allowing it to be handled and installed separately from the heavy housing. This dynamic design enables the heavy housing to remain fixed in place while lighter cassettes are swapped, improving ease of operation during installation and maintenance.
Data Source
Figure 1A~1C
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AI summary
To manufacture a large-scale electronic display having an upright orientation, a chassis (900) providing structural strength for the display is mounting on a transport jig (1500) and transported on the transport jig (1500) to an assembly line. The chassis (900) is moved on the transport jig (1500) along the assembly line and components for the display are fitted to the chassis (900) as it is moved along the assembly line. The components are preferably in the form of replaceable, modular, sub-assemblies and are fitted into the chassis 900 from a front face of the display, fitting the rearmost components first and working forward. The chassis (900) is maintained in an upright orientation from the time that it is mounted on the transport jig (1500) until the time that assembly of the display is completed on the assembly line. The assembled display remains on the transport jig (1500) for transport to a warehouse and/or to its eventual installation site. Also disclosed are means for lifting displays and means for transporting displays.