Adhesive-Bonded Cableway Cabin Corner Joint for Fatigue Resistance
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Solution Overview
Problem
Existing corner connections for cable car cabins are complex and costly to produce, and they do not adequately address the high fatigue stress and extreme weather conditions, such as extreme cold and heat, while ensuring a safe and stable support frame for at least 30 years.
Innovation Solution
A corner connection featuring a tubular support element with a hollow end and an angled connection element with a socket that forms a positive plug connection, where the inner and outer surfaces are angular, creating gaps for adhesive material to bond the elements securely, allowing for quick and easy assembly and adaptation to specific requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional corner connections with multiple work steps (drilling, tapping, screwing, or welding) are used, then the connection strength is sufficient, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention merges the support element and connection element into a single integrated corner connection component. The support element includes both the structural body and the connection element with socket, eliminating the need for separate drilling, tapping, and screwing operations. This integration reduces manufacturing steps while maintaining connection strength through the unified structure.
Solution Approach 2:
The socket is pre-formed as an integral part of the support element during the extrusion process, before final assembly. The threaded bore and connection features are created during the initial manufacturing of the support element, eliminating the need for subsequent drilling and tapping operations in the field.
2Reliability
If conventional corner connections with multiple assembly steps are used, then the connection is secure, but the assembly time and labor cost increase
Solution Approach 1:
The threaded bore and connection features are pre-formed during the extrusion process of the support element. The socket is integrated into the support element body, so no field drilling or tapping is required. This preliminary formation of connection features dramatically reduces assembly time while maintaining secure connections.
Solution Approach 2:
The support element is designed to be self-contained with all necessary connection features (socket, threaded bore, sealing surfaces) integrated into the single extruded piece. The element serves both structural and connection functions, eliminating the need for separate fastening components and reducing assembly complexity.
3Ease of manufacture
If simple cylindrical sockets are used, then the manufacturing is easier, but the connection stability under fatigue stress and extreme temperatures is insufficient
Solution Approach 1:
The socket is segmented into distinct functional zones: an enlarged reception portion for insert retention, a threaded bore for secure fastening, and sealing surfaces for environmental protection. This segmentation of functional regions within the single extruded structure provides both manufacturing simplicity and connection reliability under fatigue and temperature extremes.
Solution Approach 2:
The support element is extruded from aluminum alloy material that combines structural strength with corrosion and temperature resistance. The integrated design allows the single material to provide both structural support and connection functionality, maintaining stability under extreme conditions while remaining manufacturable.
4Strength
If corner connections require drilling, tapping, and screwing operations, then the connection is secure, but the production cost and time consumption increase
Solution Approach 1:
All connection features (socket, threaded bore, sealing surfaces) are pre-formed during the extrusion process of the support element. This preliminary creation of connection features eliminates subsequent drilling, tapping, and assembly operations, dramatically improving production efficiency while maintaining secure connections.
Solution Approach 2:
The support element and connection element are merged into a single integrated component extruded in one process. This consolidation eliminates multiple manufacturing steps and assembly operations, increasing production efficiency while maintaining connection security through the unified structure with integrated socket and threaded bore.
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
The solution enables a secure, quick, and cost-effective connection of supporting elements, providing a reliable fixation that withstands extreme conditions and ensures a stable cabin structure, allowing for easy maintenance and adaptation with suitable adhesive materials.
Implementation Method 1
An adhesive material is provided in the gap between the opposite sides of the socket end and the stem. The inner surface of the hollow end and the outer surface of the socket thus form adhesive surfaces of the corner connection and firmly bond the support element and the connecting element to one another
Data Source
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AI summary
A corner connection is provided between supporting elements of a cableway cabin. The corner connection has a supporting element (1), which takes the form of an elongate strut with a hollow end (2), and an angled connection element (3) with a connecting piece (4). The connecting piece (4) can be inserted into the hollow end (2) of the supporting element (1) in a form-fitting manner. An inner shape of the hollow end (2) and an outer shape of the connecting piece (4) are of angular design. At least two mutually opposite surfaces of hollow end (2) and connecting piece (4) are provided in a form-fitting manner in such a way that a gap (14, 14') remains between inner surface (10, 10') of the hollow end (2) and outer surface (9, 9') of the connecting piece (4), wherein an adhesive material is provided in the gap (14, 14').