Overhead Door Axle Support Stand for Spring Repair
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Solution Overview
Problem
The existing methods for repairing counterbalance springs in overhead rolling doors are time-consuming and labor-intensive, requiring specialized skills and equipment, as the entire door assembly needs to be removed and reinstalled, often necessitating heavy lifting and multiple workers.
Innovation Solution
A system and method that involves a support stand to hold and rotate the main axle of the overhead door assembly, allowing for the replacement of counterbalance springs with a cable and pulley system to pre-tension the new spring, enabling a single worker to complete the repair in under an hour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire rolling door assembly is removed and lowered to the ground for spring replacement, then the damaged spring can be accessed and repaired, but the process becomes time-consuming and labor-intensive requiring heavy lifting equipment and multiple workers
Solution Approach 1:
The patent introduces an intermediary device (a support stand with lifting mechanism) that mediates between the heavy door assembly and the worker. This device allows the door to be supported and positioned at a convenient height for spring replacement without requiring the entire assembly to be removed and reinstalled, thus reducing repair time while maintaining accessibility.
Solution Approach 2:
The patent extracts the spring replacement operation from the complete door removal process. By using the support stand to hold the door assembly in place, only the springs need to be removed and replaced, while the rest of the door remains installed. This separation of operations eliminates the time-consuming steps of complete removal and reinstallation.
2Ease of repair
If the entire rolling door assembly is removed and lowered to the ground for spring replacement, then the damaged spring can be accessed and repaired, but the process becomes labor-intensive requiring at least two men or heavy lifting equipment
Solution Approach 1:
The support stand acts as an intermediary that bears the weight of the door assembly, eliminating the need for multiple workers or heavy lifting equipment. The mechanical lifting mechanism of the support stand handles the heavy lifting task, allowing a single worker to perform the spring replacement safely and efficiently.
Solution Approach 2:
The support stand with its lifting mechanism provides self-service functionality by automatically supporting and positioning the door assembly. This eliminates the need for manual labor to hold or position the heavy door, reducing the labor requirement from multiple workers to a single operator who controls the lifting mechanism.
3Reliability
If specialized equipment and skills are used for counterbalance spring replacement, then the spring can be properly repaired, but the expense and complexity of the repair process increases
Solution Approach 1:
The support stand is designed as a universal device that can handle door assemblies of various sizes and weights. Its lifting mechanism and support structure are adaptable to different door configurations, eliminating the need for specialized equipment for each repair job. This multi-functionality maintains repair quality while reducing equipment complexity and expense.
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
This approach significantly reduces the time, labor, and expense required for repairs by allowing a single worker to efficiently replace and pre-tension the counterbalance spring without the need for heavy lifting equipment, streamlining the process from several hours to under one hour.
Implementation Method 1
The cable also secures the main axle to the support stand as the main axle is removed from the overhead door assembly and reassembled into the overhead door assembly
Implementation Method 2
A pulley wheel is then attached to the main axle. The pulley wheel is rotated by winding a cable around the pulley wheel and then unwinding the cable with a winch.
Data Source
AI summary
A system and method for supporting and rotating an axle of an overhead rolling door assembly while replacing a counterbalance spring. A support stand is provided. The support stand is positioned under the overhead door assembly. The overhead door assembly is disassembled enough to expose its main axle. The support stand is adjusted in height to engage the main axle so that the support stand holds the main axle at an elevated position. The broken counterbalance spring is replaced. The main axle is the reinstalled into the overhead door assembly. A pulley wheel is then attached to the main axle. The pulley wheel is turned by winding a cable around the pulley wheel and then unwinding the cable with a winch. This rotates the main axle with the torque needed to properly pre-tension the replacement spring.