Detachable Bridge Coupling for Weld-Free Bottom Flange Assembly

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Solution Overview

Problem

Existing bridge elements require labor-intensive welding processes to connect coupling devices to the bottom chord, which are prone to high stress and necessitate extensive inspection, complicating transportation and installation.

Innovation Solution

A detachable bolted connection system using dowel pins and a retaining element secures the coupling device to the bottom chord, eliminating the need for welding and simplifying assembly and disassembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to connect the coupling device to the bottom chord, then a reliable connection is achieved, but the process becomes labor-intensive and requires extensive inspection

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a bolted connection system (mechanical fastening system). The coupling device is connected to the bottom chord through bolts that pass through alignment holes, eliminating the need for welding operations while maintaining connection reliability. This substitution removes the requirement for highly qualified welders and reduces inspection efforts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The coupling device is divided into separate components: the coupling device itself, the bottom chord with alignment holes, and the bolts as fastening elements. This segmentation allows for simplified assembly where components are connected through discrete fasteners rather than requiring continuous welding operations, reducing manufacturing complexity while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the coupling device is permanently attached to the bottom chord, then connection reliability is ensured, but transportation and installation become more difficult

Engineering Contradiction:

Improveconnection reliabilityVSAvoidtransportation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connection system transitions from a static permanent attachment to a dynamic reversible connection. The bolted connection allows the coupling device to be securely attached during bridge assembly and operation, but can be easily detached for transportation and reattachment during installation. This dynamic capability enables the system to adapt between different operational states (transport vs. assembly).

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The bottom chord is pre-drilled with alignment holes during manufacturing, preparing the connection interface in advance. This preliminary action ensures that when the coupling device needs to be attached or detached, the alignment holes are already in place, facilitating quick and reliable bolted connections without requiring additional on-site preparation work.

Inventive Principle:

Principle #10Preliminary action

3Strength

If recesses are created in the bottom chord for coupling attachments, then connection strength is improved, but the processing becomes very labor-intensive

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly productivity

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent extracts the complex recess creation process from the manufacturing workflow. Instead of cutting recesses into the extruded bottom chord profile, the design uses the continuous bottom chord as-is and creates simple alignment holes through it. The coupling device incorporates the attachment features, eliminating the need for complex bottom chord modifications while maintaining connection strength through the bolted fastening system.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The traditional approach creates recesses in the bottom chord to accommodate coupling attachments. The patent inverts this approach by having the coupling device incorporate the attachment interface and using simple alignment holes in the bottom chord instead of recesses. This inversion simplifies the bottom chord manufacturing while achieving the same connection strength through the bolted connection geometry.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP4386142B1Bridge element with coupling device

Publication Date: 2026.03.18 KNDS DEUTSCHLAND GMBH & CO KG

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AI summary

The disclosure relates to a bridge element (1) of a relocatable bridge with a bottom flange (2) designed as an extruded profile and with a coupling device (10) attached to the bottom flange (2) for coupling the bottom flange (2) with another bridge element, wherein the coupling device (10) is detachably attached to the bottom flange (2) by means of a bolt fastening (3). The disclosure further relates to a track beam (100) of a relocatable bridge with at least two such bridge elements (1).