Box Girder Manufacturing Using Die Gap Positioning
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Solution Overview
Problem
Existing methods for producing box girders for overhead crane systems are time-consuming and require extensive positioning and alignment efforts due to the welding of bulkhead plates and side walls.
Innovation Solution
A device comprising a stationary die with a movable male part forms a circumferential gap for precise positioning of metal sheets, eliminating the need for bulkhead plates, and includes adjustable frames, pressure rollers, magnets, and a guide rail for efficient sheet metal guidance and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bulkhead plates are used to position metal sheets during welding, then the geometry of the box profile is maintained, but the production process becomes very time-consuming and requires extensive positioning and alignment activities
Solution Approach 1:
The device pre-positions the metal sheets using a frame structure with support elements before the welding process begins. The sheets are clamped and aligned in advance, eliminating the need for continuous positioning during welding and removing the requirement for bulkhead plates.
Solution Approach 2:
A frame structure acts as an intermediary device between the metal sheets and the welding process. This frame provides the positioning and support functions that previously required bulkhead plates, but allows for faster setup and removal.
2Manufacturing precision
If bulkhead plates are introduced into the box construction for positioning sheets, then the alignment of individual sheets is ensured, but a large number of positioning and alignment activities are required
Solution Approach 1:
The frame structure serves multiple functions simultaneously: it positions the metal sheets, provides support during welding, and ensures proper alignment. This multi-functional device replaces the need for separate bulkhead plates and multiple positioning components.
Solution Approach 2:
The device uses adjustable support elements and clamping mechanisms that can be positioned and secured quickly. The frame geometry and support element positions can be modified to accommodate different sheet dimensions, reducing the need for multiple specialized positioning components.
3Manufacturing precision
If the welding of bulkhead plates and side walls is performed using traditional methods, then the box profile is constructed accurately, but the process requires very time-consuming operations
Solution Approach 1:
The device enables continuous welding operations by maintaining constant support and positioning of the metal sheets throughout the process. The frame structure allows welders to work continuously without interruption for repositioning or adjustment, eliminating downtime between welding segments.
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
Enables the rapid and efficient production of box girders with minimal effort, reducing production time and eliminating the need for bulkhead plates, resulting in a lighter and more load-bearing structure.
Implementation Method 1
the die is provided with magnets at a distance from the gap formed between the die and the patrix for pre-positioning of the metal sheets that have been introduced
Implementation Method 2
the die and/or the male die are provided with pressure rollers on their sides facing the inserted metal sheets. This makes it easier to pull the sheets through the gap between the female and male parts
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a device for manufacturing a box girder (4) for a crane system, comprising an outer, stationary die (1) and a male die (2) movably arranged within the die, between which a circumferential gap is formed for inserting sheets (41, 42) which, in the position arranged between the die (1) and the male die (2), form a box. The male die (2) is connected to a cable by which the male die (2) is held horizontally in position within the die (1). The invention further relates to a method for manufacturing such a box girder (4).