Built-Up Steel Structural Elements via Segmentation
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Solution Overview
Problem
Existing prefabricated building systems face challenges in strength, durability, efficiency, modularization, and transportability due to standardized structural components that limit customization.
Innovation Solution
A method of fabricating built-up structural elements by cutting openings and bolt holes in steel hollow structural sections to vary their cross-sectional profiles, then stacking and bolting them together to form a stacked configuration, which can be coupled with complementary sections via spanning members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standardized structural steel components are used, then fabrication efficiency and consistency are improved, but customization capability and structural optimization are limited
Solution Approach 1:
The structural component is divided into multiple modular segments that can be independently fabricated using standardized processes. These segments are then assembled through connection elements (bolts, welds) to form the complete structural member, enabling both efficient standardized production and customized configurations.
Solution Approach 2:
Multiple standardized structural elements are combined through connection mechanisms to create a built-up component that functions as a customized structural solution. The merging of simple standardized parts produces complex customized structures without requiring custom fabrication of the entire component.
2Adaptability or versatility
If built-up steel components with multiple individual elements are used, then customization and structural efficiency are improved, but fabrication complexity and assembly difficulty increase
Solution Approach 1:
The built-up component is segmented into standardized modules that simplify fabrication. Each segment can be produced using common manufacturing processes, reducing fabrication complexity while maintaining customization through selective assembly of different segment combinations.
Solution Approach 2:
The connection elements and interface designs are made universal across different component types, allowing the same connection details to be used in various customized configurations. This universality reduces fabrication complexity by eliminating the need for custom connection designs for each customization scenario.
3Strength
If non-uniform cross-sectional profiles are created through cutting openings, then structural efficiency and weight optimization are improved, but manufacturing complexity increases
Solution Approach 1:
The non-uniform cross-sectional profile is achieved by segmenting the structural element and selectively removing material in standardized patterns. Rather than custom-machining each unique profile, the segmentation approach uses repeated cutting patterns that simplify manufacturing while achieving the desired structural efficiency and weight optimization.
Data Source
AI summary
A built-up structural element includes a pair of steel hollow structural sections, each having a hollow and generally rectangular cross-sectional shape, a plurality of openings, and a plurality of bolt holes distinct from the openings, wherein the steel hollow structural sections are stacked together in a stacked configuration, and a plurality of bolts extending through the plurality of bolt holes and securing the pair of steel hollow structural sections together in the stacked configuration. A built-up structural element includes a pair of steel hollow structural sections, each having a hollow and generally rectangular cross-sectional shape, a plurality of openings, and a plurality of bolt holes distinct from the openings, wherein the steel hollow structural sections are coupled to one another using a plurality of bolts extending through the plurality of bolt holes.