Selectorized Dumbbell Keyhole Assembly for Tool-Free Transport
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Solution Overview
Problem
Existing selectorized dumbbells are difficult to disassemble and reassemble, making them cumbersome for transport and storage, and they do not easily accommodate both aerobic and anaerobic exercise needs.
Innovation Solution
A selectorized dumbbell design with nested weights and a handle that can be easily disassembled into components, allowing for adjustable exercise mass without tools, and a method to use these components in both anaerobic and aerobic exercises by storing them in garments or vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rails are bolted to the weight plates with threaded fasteners requiring high torque and precision, then the attachment strength is improved, but the ease of assembly and disassembly deteriorates
Solution Approach 1:
The connection system is divided into modular components: weight plates with openings, rails with shaped ends, and separate fasteners. This segmentation allows each component to be optimized independently - the openings provide structural strength while the shaped rail ends enable tool-free engagement through simple insertion and pressing motions.
Solution Approach 2:
The shaped ends of the rails are designed to self-align and self-secure within the openings of the weight plates through simple insertion and pressing motions. The geometry of the rail ends automatically ensures proper positioning and secure attachment without requiring external tools, torque application, or precision alignment by the user.
2Manufacturing precision
If the dumbbell is shipped in an assembled form to ensure quality, then the manufacturing precision is improved, but the ease of transport deteriorates
Solution Approach 1:
The dumbbell is designed as a segmented system where the handle, weights, and connecting rails can be easily separated into individual components. This allows the product to be shipped in a compact disassembled state for easy transport and storage, while maintaining the option to assemble in various configurations. The standardized connection interfaces ensure consistent assembly quality regardless of when assembly occurs.
Solution Approach 2:
The connection system transitions from a static permanent attachment to a dynamic reconfigurable state. The rails can be easily inserted into and removed from the weight plates, allowing the dumbbell to adapt between assembled and disassembled states. This dynamic capability enables both high-quality controlled assembly at the factory and convenient user-level reassembly as needed.
3Adaptability or versatility
If a set of ten different dumbbells is used to provide various exercise masses, then the adaptability is improved, but the device complexity deteriorates
Solution Approach 1:
A single dumbbell handle is designed to universally accept multiple weight configurations through standardized connection points. The handle can be combined with different numbers and combinations of weight plates, allowing one handle to replace multiple specialized dumbbells. This multi-functionality provides the same exercise mass selection capability as a set of ten different dumbbells while reducing the total number of devices needed.
Solution Approach 2:
The weight plates are designed to nest together in a compact arrangement when not in use. Multiple weight plates can be stacked and stored in a space-efficient manner, with smaller plates fitting within or alongside larger ones. This nesting capability reduces storage space requirements and makes it practical to maintain a versatile weight collection in a single dumbbell system rather than requiring separate dumbbells for each weight.
Data Source
AI summary
A selectorized dumbbell includes a horizontal stack of nested left weight plates and a horizontal stack of spaced right weight plates with the stacks being separated by a gap into which a handle may be inserted. A selector is movable into different positions relative to the handle to vary how many nested left and right weight plates from the stacks thereof are coupled to the handle to vary the exercise mass of the handle. Each left weight plate has a counterpart right weight plate counterpart which are coupled together by at least one interconnecting member having a first keyhole slot connection between the left end of the interconnecting member and the left weight plate and a second keyhole slot connection between the right end of the interconnecting member and the right weight plate.