Adjustable Curvature Formwork With Mechanical Panel Bending
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Solution Overview
Problem
Existing formworks for producing concrete products with curved profiles, such as tunnel linings, are costly, time-consuming to set up, and prone to faults, as they require specialized construction for each project and often incorporate complex and costly electric or hydraulic systems for curvature adjustment.
Innovation Solution
A formwork system featuring a structural supporting beam and a panel connected by an adjustment device that allows simultaneous movement of intermediate and edge points to vary the panel's curvature, using mechanical drive mechanisms to distribute forces and achieve desired profiles with reduced manual effort and increased reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid intermediate elements or threaded bars are used to give fixed curvature to panels, then the panel achieves a specific curved shape, but the formwork cannot be re-utilized for different curvature requirements and setup time increases
Solution Approach 1:
The patent applies the dynamics principle by replacing rigid, fixed-curvature intermediate elements with a dynamic adjustment mechanism comprising threaded bars that can be selectively extended or retracted. This allows the panel curvature to be dynamically changed between different predetermined values, enabling the formwork to adapt to various tunnel profiles while maintaining precise curvature control through the threaded bar mechanism
Solution Approach 2:
The patent implements parameter changes by providing multiple threaded bars with different lengths that correspond to different curvature requirements. By selecting and adjusting the length of threaded bars inserted into the adjustment devices, the system can change the curvature parameter of the panel to match different tunnel profiles, thereby achieving versatility without sacrificing manufacturing precision
2Adaptability or versatility
If threaded bars are manually adjusted to vary panel curvature, then the formwork can adapt to different profiles, but a considerable amount of time is wasted in screwing or unscrewing each threaded bar
Solution Approach 1:
The patent applies preliminary action by pre-setting multiple threaded bars with different lengths corresponding to different curvature requirements. These pre-prepared threaded bars can be quickly inserted or removed from the adjustment devices without requiring time-consuming manual threading operations, thereby reducing adjustment time while maintaining profile adaptability
Solution Approach 2:
The adjustment mechanism incorporates dynamic elements that allow for rapid reconfiguration. The threaded bars are designed to be easily inserted and locked into the adjustment devices, enabling operators to quickly switch between different curvature settings by simply replacing bars rather than manually adjusting each one, thus significantly reducing the time loss associated with curvature changes
3Extent of automation
If hydraulic pistons or electric motors are used to vary panel curvature, then curvature adjustment is automated, but production and maintenance costs increase considerably
Solution Approach 1:
The patent replaces complex hydraulic or electromechanical systems with a simpler pure mechanical adjustment mechanism. Threaded bars with external threads engage with corresponding threaded holes in the adjustment devices, allowing for manual or semi-automated curvature adjustment without requiring hydraulic pistons or electric motors. This substitution dramatically reduces production and maintenance costs while still providing effective curvature control
Solution Approach 2:
The threaded bar mechanism is designed to be self-contained and self-explanatory in its operation. The external threading on the bars allows them to be directly inserted and engaged with the adjustment devices without requiring additional actuators, control systems, or power sources. This self-service design eliminates the need for expensive hydraulic or electrical components while maintaining the ability to adjust panel curvature effectively
4Manufacturing precision
If control systems are implemented to manage actuators for panel curvature, then precise curvature control is achieved, but the formwork becomes more complex and more liable to faults
Solution Approach 1:
The patent eliminates the need for complex control systems by replacing electromechanical actuators with a purely mechanical threaded bar adjustment mechanism. The precision of curvature control is achieved through the mechanical engagement of the threaded bars with the adjustment devices, where the thread pitch and bar length precisely determine the panel curvature. This mechanical substitution removes all electronic control components, reducing device complexity and fault susceptibility while maintaining manufacturing precision
Solution Approach 2:
The threaded bars are designed as simple, replaceable mechanical elements that can be easily manufactured and replaced if needed. Rather than investing in expensive, complex control systems and actuators that require maintenance and are prone to failure, the patent uses multiple simple threaded bars that can be quickly swapped out. This approach reduces overall system complexity and eliminates the need for sophisticated control electronics while maintaining precise curvature control through the mechanical threading mechanism
Data Source
AI summary
Disclosed is a formwork for producing concrete products including at least one supporting beam with an axis of extension, at least one panel bendable around a transverse direction with respect to the axis and at least one adjustment device adapted to connect the panel to the beam and to vary the curvature of the panel between a flat undeformed condition and curved condition, where the outer surface is convex or, if necessary, concave, wherein the adjustment device is connected at least at one intermediate point of the panel and at least at one edge point, positioned at a lateral edge substantially parallel to the direction of curvature, in order to simultaneously move the points to vary the curvature of the outer surface of the panel.