Standardized Roller Door Frame Components for Modular Assembly
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Solution Overview
Problem
The complexity and cost of manufacturing, assembling, and maintaining roller door gate frames with custom dimensions and functionalities pose logistical challenges for globally operating manufacturers, including high tool costs, extensive spare part inventory needs, and delayed repairs due to the requirement for numerous specialized tools and qualified personnel.
Innovation Solution
A gate frame design utilizing standardized components, comprising a frame profile, frame cover, and connecting elements, which allows for adaptable and stable construction with reduced tooling costs and simplified logistics, featuring a frame profile with channels for component accommodation and a connecting element that enhances stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If door frames are designed with custom dimensions and functionalities to meet specific application requirements, then the adaptability and functionality are improved, but the manufacturing complexity and tooling costs increase
Solution Approach 1:
The door frame is divided into modular components (frame profile, frame cover, connecting elements) that can be independently manufactured using standardized processes. This segmentation allows each component to be produced with standard tools while the final assembly achieves custom configurations, resolving the contradiction between customization and manufacturing complexity.
Solution Approach 2:
The standardized components are designed with universal features that allow them to serve multiple functions and be configured for different applications. The frame profile and cover can be adapted to various door frame types while maintaining the same manufacturing process, enabling both versatility and simplified production.
2Manufacturing precision
If a large number of specialized tools are manufactured to produce all different door frame components and variants, then the manufacturing precision and customization capability are improved, but the tooling costs and inventory requirements increase
Solution Approach 1:
A small set of standardized components is designed to serve multiple functions across different door frame applications. This universality allows the same tools to manufacture various components for different door frame types, eliminating the need for extensive specialized tooling while maintaining manufacturing precision through standardized production processes.
3Loss of time
If spare parts are produced and stored in advance to ensure rapid availability, then the response time for repairs is improved, but the storage costs and logistical complexity increase
Solution Approach 1:
The door frame is segmented into a limited number of standardized components, which reduces the total variety of spare parts that need to be stocked. This segmentation enables manufacturers to maintain lower inventory levels while still being able to service a wide range of door frame configurations, thus reducing storage costs and logistical complexity.
Solution Approach 2:
Standardized components with consistent dimensions and specifications allow for parameter-based inventory management. Instead of stocking unique parts for each custom configuration, manufacturers can stock standardized components that can be adapted to different applications through assembly variations, significantly reducing the spare part inventory required.
4Reliability
If specialized personnel are deployed for installation and repair work on special designs, then the installation quality and reliability are improved, but the labor costs and response time increase
Solution Approach 1:
The door frame system is divided into standardized, self-explanatory modules that can be easily identified and assembled. This segmentation creates a user-friendly system where local service personnel can perform installation and repair work without requiring specialized expertise, reducing both labor costs and response time while maintaining installation quality through standardized procedures.
Data Source
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AI summary
The present invention relates to a door frame (10) comprising a frame profile (12), a frame cover (14), and at least one connecting element (16) linking the frame profile (12) and the frame cover (14). To reduce the complexity of manufacturing, assembling, maintaining, and repairing the door frame (10) and to simplify the rapid availability of its components, the frame profile (12) and/or the frame cover (14) consist of standardized components. Furthermore, the invention relates to a roller door with at least one such door frame (10).