Built-Up I-Beam Assembly for Custom Deep Lightweight Structures
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Solution Overview
Problem
Standardized structural steel components are limited in customization, leading to inefficiencies in specific use cases, as they cannot be tailored to optimize performance for particular applications.
Innovation Solution
A method of fabricating built-up beams by cutting web openings, flange openings, and bolt holes in I-beams to vary their cross-sectional profile, allowing them to be stacked and bolted together with beam spanning members, creating a customized, deep, yet lightweight structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standardized structural steel components are used, then manufacturing efficiency and consistency are improved, but customization capability deteriorates
Solution Approach 1:
The beam is divided into multiple I-beam components that can be independently manufactured using standardized processes, then assembled together. This segmentation allows each component to be produced efficiently while the overall structure achieves customization through selective assembly and configuration of these standardized segments.
Solution Approach 2:
Standardized I-beam components serve multiple functions: they can be used individually or combined in various configurations to create different beam structures. The universal I-beam design allows the same basic component to fulfill both standardized production requirements and customized structural needs through different assembly arrangements.
2Adaptability or versatility
If built-up beam configuration is used, then customization capability is improved, but device complexity increases
Solution Approach 1:
The complex built-up beam is segmented into simpler I-beam components that are easier to manufacture and handle individually. The apparent complexity of the final structure is managed by breaking it down into standardized segments that can be produced using常规 processes, then assembled through systematic connection methods.
Solution Approach 2:
Multiple simple I-beam components are merged together to create the customized built-up beam structure. This merging process transforms individually simple components into a complex customized structure, allowing the system to achieve high adaptability while keeping individual component complexity low.
3Weight of moving object
If built-up beam configuration is used, then weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
Openings and connection features are pre-formed in each I-beam component during the manufacturing stage with high precision. This preliminary action ensures that when components are assembled on-site, the precision requirements are already met, reducing the burden on field assembly operations and ensuring accurate alignment without requiring complex field measurement and adjustment procedures.
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
This approach enables the creation of customized structural beams that are both deep and lightweight, improving load-carrying capacity and reducing weight by up to 45%, while allowing for efficient assembly and disassembly, reducing manufacturing and shipping costs.
Implementation Method 1
Cutting the plurality of web openings and the plurality flange openings in each I-beam may include CNC thermal cutting each of the openings
Data Source
AI summary
A built-up beam includes a pair of I-beams each having opposing flanges, a web that extends between the opposing flanges, a plurality of flange openings in each of the opposing flanges, a plurality of web openings in the web, and a plurality of bolt holes in one of the opposing flanges. The I-beams are stacked together flange-to-flange in a stacked beam configuration and a plurality of bolts extend through the plurality of bolt holes and secure the pair of I-beams together in the stacked beam configuration.