Modular Bridge Cap Fastening for Corrosion-Resistant Assembly
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Solution Overview
Problem
Existing bridge cap fastening units require significant manufacturing and assembly effort, and are not easily adaptable to different bridge cap thicknesses, leading to high production and assembly costs and potential corrosion issues.
Innovation Solution
A modular fastening unit composed of separate parts, including a cylindrical anchor sleeve, transition piece, compensating sleeve, and cover, which allows for easy assembly, adaptation to varying thicknesses, and enhanced corrosion resistance, with the option for preassembly and adjustable components for flexible installation angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bridge cap is attached using fasteners guided through openings with lost anchor sleeves and lid covers, then watertightness and corrosion resistance are improved, but manufacturing and assembly complexity increases
Solution Approach 1:
The fastening unit is divided into separate modular components: a guide device with anchor sleeve, a transition piece, and a base section with screw anchors. These segments can be manufactured independently and assembled, reducing overall manufacturing complexity while maintaining the protective functions of the original design
Solution Approach 2:
The lid cover and anchor sleeve are designed as removable components that can be taken out during assembly and installation. This extraction approach simplifies the manufacturing process by allowing separate production of components and facilitates easier assembly compared to integrated designs
2Reliability
If a fixed design of opening with anchor sleeve and lid is used, then corrosion resistance is achieved, but adaptability to different bridge cap thicknesses is reduced
Solution Approach 1:
The fastening unit incorporates adjustable elements including the base section with screw anchors that can be positioned at different depths, and the transition piece that accommodates varying distances between the anchor sleeve and the outer surface. This dynamic adjustability allows the same fastening unit to adapt to bridge caps of different thicknesses while maintaining corrosion protection
Solution Approach 2:
The guide device and anchor sleeve assembly serves multiple functions: it provides corrosion protection, guides the fastening elements, and adapts to different thickness configurations. This multi-functionality increases versatility without sacrificing the corrosion resistance achieved through the protective design
3Ease of manufacture
If separate individual parts are used in the fastening unit, then manufacturing and assembly costs are reduced, but device complexity increases
Solution Approach 1:
The fastening unit is segmented into distinct components (guide device, transition piece, base section) that can be manufactured using standard processes and assembled relatively simply. This segmentation enables cost-effective production while the modular nature actually reduces overall complexity compared to monolithic designs
4Ease of manufacture
If standard parts like tubes are used for anchor sleeve, then production costs are reduced and adaptability improved, but manufacturing precision may be compromised
Solution Approach 1:
The transition piece acts as an intermediary component that connects the standard anchor sleeve tube to the base section with screw anchors. This mediator compensates for any dimensional tolerances of the standard tube part, ensuring proper alignment and fit without requiring custom-machined anchor sleeves, thus maintaining both cost-effectiveness and manufacturing precision
Data Source
Figure 1
Figure 2~3B
Figure 4A~5B
AI summary
A bridge cap (70) which has, for fastening to a bridge (90), a fastening unit (1) with a fastening means (80) and with a guide device (10) which comprises a cylindrical anchor sleeve (50). The invention further relates to a fastening unit (1) for fastening a bridge cap (70). A low outlay in terms of manufacture and assembly is achieved in that the fastening unit (1) is composed of separate individual parts which, besides the anchor sleeve (50), comprise a separate transition piece (40) having a first cylindrical portion (44) adapted to the diameter of the anchor sleeve (50) and a second cylindrical portion (42) facing away from the first and directed towards an outer side (74) of the bridge cap (70).