Modular Scaffolding End Connector Alignment and Locking Mechanism
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Solution Overview
Problem
Current modular scaffolding end connectors suffer from misalignment issues due to metal deformation, leading to a twisted design that can cause safety hazards and prevent proper engagement with vertical scaffold members, and lack a secure positive lock against twisting forces.
Innovation Solution
A new end connector housing design where each sidewall is separately formed and assembled using a jig to ensure proper alignment, combined with a locking latch mechanism featuring a rotating upper and lower latch that interfere to provide a secure lock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end connector housing is formed by bending and stretching metal, then the connector can be manufactured, but misalignment and twisting occur due to metal deformation
Solution Approach 1:
The end connector housing is divided into two separate sidewalls that are formed independently and then assembled together using a jig. This segmentation prevents metal deformation from affecting the entire housing, as each sidewall can be formed separately with controlled alignment, eliminating the twisting issues caused by bending and stretching a single piece of metal.
2Device complexity
If a simple latch mechanism is used, then the device complexity is reduced, but the connector lacks a secure positive lock against twisting forces
Solution Approach 1:
The latch mechanism combines two rotating members (upper and lower latches) that work together to provide a secure positive lock. The latches are arranged to interfere with each other, creating a interlocking mechanism that resists both upward and twisting forces. This merging of multiple latch elements provides enhanced reliability while maintaining reasonable device complexity.
3Manufacturing precision
If the sidewalls are formed separately and assembled using a jig, then alignment precision is improved, but the device complexity increases
Solution Approach 1:
A jig is introduced as an intermediary tool during the assembly process to ensure precise alignment of the two separately formed sidewalls. The jig provides fixed reference points and guides that maintain consistent spacing and orientation, achieving high alignment precision without requiring complex direct attachment mechanisms between the sidewalls.
Data Source
AI summary
An end connector for a horizontal scaffold member includes two sidewalls that are substantially parallel joined to a pipe. Each side wall has two spaced apart engagement section. The sidewalls extend into the interior of the pipe and remain substantially parallel in the interior of the pipe. A movable latch is positioned between the two sidewalls.