Reformer Frame Corner Extrusion for Secure Level Adjustment
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Solution Overview
Problem
Existing corner members for physical exercise apparatus frames, such as reformers, lack effective structural support and secure fastening mechanisms, leading to instability and potential misalignment when the floor is uneven.
Innovation Solution
A corner member designed as an elongated hollow metal extrusion with a central corner portion and leg portions, featuring discrete surface features and axial ribs for secure engagement and retention of frame side and end members, along with apertures for fasteners, providing enhanced structural support and adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional corner members are used for reformer frames, then the device complexity is low, but the structural support and stability are insufficient
Solution Approach 1:
The corner member is divided into distinct functional segments: a receptacle portion for receiving frame members, a body portion providing structural support, and an adjustment mechanism with threaded bores. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
The frame side and end members are nested within the receptacle portion of the corner member. The receptacle is configured to receive these members in a nested arrangement, where the frame members are inserted into and retained by the receptacle structure, creating a compact and integrated assembly.
2Reliability
If traditional corner members are used, then the manufacturing process is simple, but the fastening mechanism is insecure
Solution Approach 1:
The corner member incorporates pre-formed threaded bores and discrete surface features (such as knurling or ribs) that are integrated into the manufacturing process. These features are prepared in advance during the extrusion or machining process, eliminating the need for separate fastening components and simplifying assembly while ensuring secure retention.
Solution Approach 2:
The corner member includes built-in retention features such as threaded bores and surface textures that automatically grip and retain the frame members. The discrete surface features on the inner walls of the receptacle create friction and mechanical interlocking, allowing the structure to secure itself without additional fasteners.
3Adaptability or versatility
If traditional corner members are used, then the device is simpler, but the adaptability to uneven surfaces is poor
Solution Approach 1:
The corner member incorporates an adjustment mechanism with threaded bores that allow the position of the frame members to be dynamically adjusted. This enables the reformer frame to be adapted to uneven surfaces by adjusting the height or position of corner members, transforming a static structure into an adaptable one.
Solution Approach 2:
The corner member design allows for changing the vertical position parameter of the frame members through the threaded adjustment mechanism. By rotating the threaded bores or associated adjustment components, the height of the corner member can be modified to compensate for uneven surfaces, providing versatility in different installation conditions.
4Strength
If traditional corner members are used, then the assembly is simpler, but the structural integrity on uneven surfaces is compromised
Solution Approach 1:
The corner member combines multiple functions into a single integrated component: the receptacle for receiving frame members, the body for structural support, and the adjustment mechanism for level compensation. This merging ensures that structural integrity and adjustment capability work together as a unified system, maintaining strength while enabling adaptation to uneven surfaces.
Data Source
AI summary
A frame corner member includes an elongated hollow extrusion having a central corner portion and two leg portions extending from the central portion. Each leg portion includes an inner side wall spaced from and parallel to an outer side wall, and merging with the central portion. An outer end wall joins the inner and outer side walls, which each include an inner surface facing the inner surface of the other side wall. An opening through the outer end wall defines a space between the inner and outer side walls adjacent one end of the extrusion for receiving one end of one of frame side members and end members. At least one of the inner surfaces in the space has discrete surface features adapted to grip and retain the one end of one of the side members and end members in the space when received through the opening.