Six-Way Box Connectors for Tool-Free Modular Truss Assembly
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Solution Overview
Problem
Conventional truss systems for supporting lighting and other structures in temporary settings, such as stages and trade shows, require tools for assembly and disassembly, are not quick or easy to configure, and lack the necessary portability and durability for frequent reuse.
Innovation Solution
A modular truss system utilizing six-way box connectors with matching center holes and spring pin arrangements on truss beams and end plates, allowing for tool-free assembly and configuration in various orientations, enhancing speed, security, and portability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional truss systems use tube-in-socket or bolted end plate connections, then structural strength is maintained, but assembly requires tools and time
Solution Approach 1:
The connector is divided into separate male and female components with complementary geometries. The male connector protrudes from one truss end while the female connector recesses into the other, allowing tool-free assembly through simple insertion and rotation without requiring bolts or additional fasteners.
Solution Approach 2:
The connector design enables self-aligning and self-securing through its geometric features. The protruding male component automatically finds the recessing female component, and the spring pins with collar buttons provide self-contained fastening without external tools, making the assembly process autonomous and tool-free.
2Ease of operation
If truss systems are designed for quick assembly, then portability improves, but connection security may be compromised
Solution Approach 1:
Spring pins are pre-installed in the connector boxes during manufacturing, positioned to engage with corresponding holes in the truss ends. This preliminary preparation ensures that when assembly occurs, the connection security is immediately established through the spring pins and collar buttons without requiring additional fastening steps.
Solution Approach 2:
Collar buttons serve as intermediary elements between the spring pins and the truss end plates. These collar buttons provide a visible and tactile indicator of proper connection, while also distributing the load and securing the spring pins in place, thereby enhancing connection security without complicating the assembly process.
3Adaptability or versatility
If modular connectors are used for versatility, then adaptability increases, but device complexity increases
Solution Approach 1:
The connector design uses identical male and female components that can be applied to any truss end, regardless of orientation or configuration. The same basic connector geometry works for all six faces of a cube truss section, allowing unlimited configuration possibilities while using a single standardized component design, thereby reducing overall system complexity.
Data Source
AI summary
A modular truss system includes six-way box connectors to which truss beams can be bolted and pinned together in a wide variety of configurations and to any or all of the six identical faces. Each box connector face and each truss beam endplate is fitted with matching center holes for bolts and spring pin arrangements on the peripheral corners. These make aligning and attaching the truss beams and box connectors to one another a quick and simple job that does not require any tools. The truss beam endplates have one or more spring pins and a center hole that matches the ones in each of the six faces of the box connectors.