Mast Elements for Construction Machines with Integrated Guide Webs
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Solution Overview
Problem
Existing mast elements for construction machines face issues with distortion, corrosion, and weakened connections due to welding seams on high-load regions, which affect strength and durability, particularly when using fiber-reinforced materials or steel connections.
Innovation Solution
A mast element design featuring guide profiles with integrated connecting webs that relocate welded seams away from high-load areas, using hollow profiles and reinforcing elements to enhance stability and reduce distortion, with optional diagonal stiffening for increased torsional stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If guide strips are welded laterally onto the hollow mast profile, then the linear guide is formed, but distortion and deterioration of guide surfaces occur
Solution Approach 1:
The guide strip is divided into a guide profile and separate connecting webs. The guide profile forms the guide surfaces while the connecting webs provide welding surfaces, separating the functional guide surfaces from the welding zones to prevent distortion and deterioration of the guide surfaces during welding operations
Solution Approach 2:
Connecting webs act as intermediary elements between the guide strip and the mast profile. These webs serve as dedicated welding surfaces that transfer the welding heat and mechanical connection away from the guide surfaces, preventing direct welding on the guide strip and thus avoiding distortion and surface deterioration
2Ease of manufacture
If welding is performed on corner edges of the hollow mast profile, then connection is achieved, but strength and durability are reduced
Solution Approach 1:
The welding function is extracted from the corner edges and relocated to the connecting webs. By removing the welding operation from the high-load corner regions and placing it on the connecting webs instead, the corner edges are no longer subjected to welding heat and mechanical stress concentration, thereby maintaining their full strength and durability
Solution Approach 2:
The connecting webs serve as intermediary welding surfaces that bridge the guide strip to the mast profile without involving the corner edges. This intermediary structure allows welding to occur in low-stress regions while maintaining strong connection, as the connecting webs distribute the welding stresses away from the critical corner load-bearing areas
3Weight of moving object
If fiber reinforced materials are used for the mast element, then weight is reduced, but processing becomes time-consuming and costly
Solution Approach 1:
The mast element is segmented into a fiber reinforced mast profile and separate steel guide strip assemblies. This segmentation allows the fiber reinforced material to be processed separately for the mast profile, while the steel guide strips can be manufactured and assembled using conventional, well-established processes, thereby reducing overall processing complexity and time
Solution Approach 2:
The mast element uses composite construction combining fiber reinforced materials for the mast profile with steel guide strips for the linear guide system. This composite approach leverages the lightweight properties of fiber reinforced materials while using readily available, easily processable steel for the guide components, balancing weight reduction with manufacturing efficiency
4Ease of manufacture
If welded seams are placed on high-load regions, then connection is achieved, but corrosion resistance is reduced
Solution Approach 1:
The welding operation is extracted from the high-load corner regions and relocated to the connecting webs. By removing welding from the corner edges where mechanical stress and corrosion synergistically act, the welding seams are positioned in regions with lower mechanical tension, thereby improving overall corrosion resistance
Solution Approach 2:
The connecting webs serve as intermediary structures that separate the welding zones from the high-stress corner regions. This intermediary arrangement allows welded connections to exist in low-stress areas while the corner edges remain unwelded and thus more resistant to corrosion, as they avoid the harmful effects of welding heat and subsequent corrosion-prone surfaces
Data Source
AI summary
The invention relates to a mast element, in particular a leader element, for a construction machine, with an elongate hollow mast profile which, at a front side, is provided along a mast longitudinal direction with two guide strips through which a linear guide for a mast carriage is formed along the front side. According to the invention, provision is made that at least one guide strip is designed as part of a guide profile on which at least one connection web is formed in one piece with the guide strip, which connection web extends away from the guide strip, and that, in order to form the hollow mast profile, elongate wall elements are provided which, together with the at least one connection web, form the hollow mast profile and enclose an inner cavity of the mast profile.