Telescoping Exercise Frame Uprights for Compact Shipping
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Solution Overview
Problem
Conventional weight lifting frames with uprights formed as single, long steel tubes pose shipping challenges due to their non-uniform dimensions, leading to increased risk of damage during transportation, as they are often packaged in boxes that are too short and wide, encouraging stacking of heavier loads on top.
Innovation Solution
The frame is designed with vertically extending uprights formed from separable sections, each comprising two telescoping parts with an interference fit, allowing for assembly and disassembly using specialized tools, which reduces the length of the packaged components while maintaining structural integrity and adjustability of bar supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uprights are formed as single long steel tubes, then structural strength and rigidity are maintained, but shipping safety deteriorates due to non-uniform dimensions causing stacking of heavier loads on top
Solution Approach 1:
The upright is divided into multiple telescoping sections (first section, second section, third section) that can be nested within each other during shipping. This segmentation allows the components to be packaged in uniform, taller cartons that are less likely to be damaged by stacked loads, while still providing the required structural strength when assembled.
Solution Approach 2:
The telescoping sections are designed to nest within each other when disassembled, with each section having a slightly larger outer dimension than the inner section. This nesting capability enables compact packaging in uniform cartons, improving shipping safety while maintaining the ability to form a long, strong upright structure when assembled.
2Strength
If uprights are formed as single long steel tubes, then structural integrity is maintained, but packaging efficiency deteriorates due to non-uniform dimensions
Solution Approach 1:
The upright is segmented into multiple sections of manageable lengths that can be packaged in uniform cartons. Each section maintains sufficient structural integrity on its own, and when telescoped together, they form the complete upright with the required overall strength and rigidity.
Solution Approach 2:
The design transitions from a single-dimension problem (one long tube) to a multi-dimensional solution where multiple shorter sections are arranged in a telescoping configuration. This allows the components to occupy a more uniform packaging volume while maintaining the necessary structural properties.
3Object-affected harmful factors
If uprights are divided into separable sections, then shipping safety is improved by allowing uniform packaging, but device complexity increases due to assembly and disassembly requirements
Solution Approach 1:
The telescoping sections are designed to nest within each other using simple interference fits between adjacent sections. This nesting mechanism provides a straightforward assembly and disassembly process that reduces complexity compared to other multi-component connection systems, while still enabling uniform packaging for improved shipping safety.
Solution Approach 2:
The telescoping sections utilize self-aligning features and interference fits that allow the sections to assemble and disassemble without requiring complex tools or procedures. The design enables users to easily connect and disconnect the sections by simple pushing and pulling motions, minimizing the increase in operational complexity.
4Strength
If telescoping sections with interference fit are used, then structural rigidity is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The design uses controlled parameter changes in the interference fit dimensions to achieve the desired balance between structural rigidity and manufacturing feasibility. By carefully selecting the interference fit parameters (clearances, tolerances, material properties), the sections can be manufactured with standard precision capabilities while still providing sufficient rigidity when assembled.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design allows for safer and more efficient shipping by reducing the likelihood of damage, as the components can be packed in a more uniform and taller carton, maintaining the strength and rigidity of traditional frames while enabling adjustable coupling of bar supports.
Implementation Method 1
The reduced size end of the one section and the one end of the other section will have an interference fit therebetween when the sections are telescopically interfit with one another which is sufficiently tight such that the sections can be telescopically interfit with one another only by using a force that is greater than the force a user can exert using hand pressure to push the sections together
Data Source
AI summary
An exercise equipment frame, such as a power cage, is formed from uprights that comprise at least two sections that are telescopically interfit with one another. The sections have an interference fit between them when the telescopic interconnection is made that is tight enough to require the use of a tool that enables leverage greater than that achievable by the hand pressure of a user. The sections may be of substantially equal length to one another when forming the main uprights of the frame to allow packaging of the sections when disassembled in a carton of more regular dimensions. The sections may also be unequal length to allow coupling of a frame extension to the top of a completed power cage type frame.