Rail System Profile Prefabrication for Door Assembly
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Solution Overview
Problem
Existing methods for assembling rail systems for doors, such as overhead doors, require significant stock, tools, and operations, and result in high cutting losses and prolonged assembly times due to the need for on-site cutting and hole formation of reinforcement, runner, and mounting profiles.
Innovation Solution
A method that involves prefabricating profiles with discrete lengths and bending angles, allowing for minimal processing at the installation site, using a computer program to optimize profile selection and manufacturing, enabling efficient assembly and installation with reduced material loss and tool requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If profiles are cut and processed at the worksite to achieve required lengths and configurations, then the rail system can be assembled on-site, but cutting losses increase and assembly time is prolonged
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-fabricating profiles with discrete lengths and bending angles before delivery to the worksite. The computer program determines the exact profile requirements based on the specific rail system configuration, and profiles are manufactured to precise specifications in advance, eliminating the need for on-site cutting and reducing material waste.
2Adaptability or versatility
If profiles are cut and processed at the worksite, then the rail system can be adapted to specific installations, but assembly time increases
Solution Approach 1:
The computer program performs preliminary calculation and planning of the entire profile package requirements before manufacturing. Profiles are produced with discrete lengths and pre-formed bending angles that match the specific installation needs, allowing rapid on-site assembly without time-consuming cutting and processing operations.
Solution Approach 2:
The patent utilizes discrete parameter values for profile lengths and bending angles (e.g., specific length increments and standard bending angles like 30° or 45°). This discretization allows the system to maintain flexibility for various configurations while enabling efficient manufacturing and assembly, as profiles with these standardized parameters can be quickly produced and assembled.
3Ease of operation
If tools are provided at the client site for cutting and punching profiles, then on-site processing is enabled, but tool requirements and complexity increase
Solution Approach 1:
The patent extracts the complex cutting and punching operations from the on-site assembly process. Instead of providing clients with cutting tools, punching equipment, and associated fixtures, the solution delivers pre-fabricated profiles that have already undergone these operations in a controlled manufacturing environment, significantly reducing the tool inventory and complexity required at the worksite.
4Loss of substance
If complete profile packages are prefabricated with predetermined dimensions, then material loss is reduced, but manufacturing setup complexity increases
Solution Approach 1:
The computer program uses parameter changes by discretizing profile lengths and bending angles into standardized increments. This allows the manufacturing process to efficiently produce a variety of profile configurations by adjusting discrete parameters rather than requiring complex custom manufacturing for each unique dimension, reducing both material waste and manufacturing complexity.
Solution Approach 2:
The patent applies local quality by providing profiles with specific discrete lengths and bending angles tailored to the local requirements of each rail system configuration. The computer program analyzes the specific installation geometry and determines the exact profile parameters needed, ensuring that each profile in the package is optimally dimensioned for its specific position and function in the assembly.
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~3c
AI summary
A description is given of a method in which profiles which are to be assembled for a rail system which is suitable for guiding movable doors are selected from the following profiles: a) at least one reinforcement profile having a minimum length and a maximum length and provided with fixing holes, and manufacturable discrete profile lengths to be selected in between said minimum length and said maximum length; and b) at least one runner profile having a minimum length and a maximum length and provided with fixing holes, and manufacturable discrete runner profile lengths to be selected in between said minimum length and said maximum length; and c) at least one mounting profile having a minimum length and a maximum length and provided with fixing holes for the reinforcement profile and/or the runner profile, and manufacturable discrete mounting profile lengths to be selected in between said minimum length and said maximum length; and at least one bend profile having a minimum bending angle and a maximum bending angle and provided with fixing holes for the runner profile, and manufacturable discrete bending angles to be selected in between said minimum bending angle and said maximum bending angle.