Beam-End Welding Fixture for Precise Connection Alignment
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Solution Overview
Problem
The challenge in steel frame construction is achieving precise positioning and welding of beam connections to maintain specifications, as imprecisions in manufacturing can lead to overall deviations due to the accumulation of tolerances along the length of the building frame, requiring advanced tools and methods for precise positioning and welding of beam connection components.
Innovation Solution
A beam-end component welding system comprising first and second welding fixtures and a beam support, configured to maintain precise spatial relationships during welding, with features like laser distance finding tools, adjustable and removable components, and safety latches to ensure secure and accessible welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional on-site welding techniques are used for beam connections, then construction flexibility is maintained, but manufacturing precision and spatial orientation accuracy deteriorate due to tolerance accumulation
Solution Approach 1:
The welding fixture is divided into multiple independent components including adjustable support structures, positioning clamps, and modular alignment tools. Each component can be independently adjusted and positioned to achieve precise spatial orientation without requiring a single complex fixed fixture system.
Solution Approach 2:
The fixture incorporates adjustable and reconfigurable elements that can be dynamically positioned during the welding process. Supports and clamps can be moved to accommodate different beam configurations while maintaining precise positioning, allowing the system to adapt to various manufacturing requirements without sacrificing accuracy.
2Manufacturing precision
If precise positioning fixtures are used during welding, then manufacturing precision is improved, but ease of operation deteriorates due to restricted worker access
Solution Approach 1:
The positioning system uses multiple separate support points and adjustable clamps distributed around the beam rather than a single encompassing fixture. This segmentation allows welders to access different areas of the beam from multiple angles while each positioning element maintains its function independently.
Solution Approach 2:
The fixture design incorporates three-dimensional positioning capabilities with supports arranged in vertical, horizontal, and angular dimensions. This multi-dimensional approach allows precise spatial control of the beam while leaving traditional welding approach paths open, as positioning is achieved through coordinated adjustment in multiple directions rather than restricting access from a single plane.
3Productivity
If multiple beam connections are manufactured along the building frame length, then construction scale is increased, but overall deviation from specifications worsens due to tolerance multiplication
Solution Approach 1:
The fixture system establishes precise reference positions and alignment benchmarks before each welding operation begins. By pre-positioning supports, clamps, and alignment tools according to exact specifications, the system resets the tolerance baseline for each connection, preventing cumulative deviation from propagating through multiple manufactured joints along the building frame.
Data Source
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AI summary
A beam-end component welding fixture is disclosed, including a stand having a central horizontal axle mechanism and a housing. A handle is mounted on a first end portion of the axle mechanism and a rotatable plate structure is mounted on a second end portion of the axle mechanism. A column connecting simulator is attached to the plate structure and configured to support a beam-end component.