Anchor Rail Positioning in Precast Concrete Formwork
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Solution Overview
Problem
Existing methods for producing precast concrete parts with embedded anchor rails face challenges in simple and precise positioning and fixing, as well as efficient detachment of holding elements, which hinders the reuse of these elements in subsequent production processes.
Innovation Solution
A device with a retaining element that has a threaded bore on its underside and is fastened to the formwork using a screw, allowing for secure attachment and easy detachment, featuring a common through-hole for cost reduction, and a holding element designed as a truncated cone or elongated shape with a fastening screw made of low-breaking-strength plastic or durable materials like steel, along with a seal to prevent concrete penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If anchor rails are fixed to formwork using conventional fastening methods (screws, bolts, welding), then the anchor rails are securely positioned, but the detachment of holding elements becomes complex and time-consuming
Solution Approach 1:
The fastening system is divided into two distinct parts: a permanent retaining element that remains attached to the formwork, and a removable fastening element that secures the anchor rail during production. This segmentation allows the retaining element to provide reliable positioning while the fastening element can be quickly removed after use, enabling reuse of the retaining element without time-consuming detachment operations.
Solution Approach 2:
The fastening element acts as an intermediary between the retaining element and the anchor rail. It provides the secure connection needed during concrete production, then can be removed and reused on the next formwork, avoiding the need to detach permanent retaining elements and eliminating time losses.
2Productivity
If retaining elements are removed from formwork after each use, then they can be reused, but the positioning and fixing process becomes more complex
Solution Approach 1:
The system separates the retaining element (permanent attachment to formwork) from the fastening element (removable). The retaining element with its threaded bore remains on the formwork for repeated use, while only the simpler fastening element needs to be attached and removed. This segmentation enables reuse without increasing overall system complexity.
Solution Approach 2:
Multiple identical retaining elements can be manufactured as copies and distributed across the formwork. Each retaining element is simple in design with a threaded bore for the fastening element, allowing easy replication and consistent positioning across different production cycles without complex customization.
3Reliability
If multiple separate components are used for fastening (retaining element, fastening element, screw), then the anchor rail can be securely fixed, but manufacturing costs increase
Solution Approach 1:
The retaining element and fastening element are merged into a single integrated component. The retaining element contains a threaded bore that directly receives the fastening element, eliminating the need for separate screws or additional fastening hardware. This merging reduces the number of parts, simplifies manufacturing, and lowers costs while maintaining secure fixation.
Solution Approach 2:
The retaining element serves multiple functions: it provides a mounting point on the formwork, contains the threaded bore for fastening, and remains reusable across production cycles. This multi-functionality reduces the need for additional specialized components, simplifying the overall fastening system and reducing manufacturing costs.
Data Source
Figure 1
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Figure 5~8
AI summary
In a formwork for the production of precast concrete elements, precast concrete elements with embedded anchor rails (2) can also be cast. The anchor rail (2) has a substantially C-shaped cross-section, with a rail back (3) on which anchors for embedding in the precast concrete element (6) are arranged. The anchor rail also has a longitudinal slot (4) facing the formwork (1, 26). A device for positioning and fixing the anchor rail (2) is provided on the formwork (1), wherein the device comprises at least one retaining element (9) for each anchor rail (2) arranged on the formwork (1), which projects through the longitudinal slot (4) into the anchor rail (2). The retaining element (9) is connected to the anchor rail (2) before the concrete is poured into the formwork (1). After the concrete has hardened, the retaining element (9) can be detached from the anchor rail (2, 25) and removed from it through the longitudinal slot.