Crane Structural Frame with 3D Printed Reinforcement Layers
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Solution Overview
Problem
Existing structural frames for machines like cranes face challenges in achieving lightweight construction while maintaining sufficient strength, as they are often overdimensioned in less loaded regions due to prioritizing safety-reliable strength, which complicates manufacturing, especially with metal materials.
Innovation Solution
The structural frame incorporates integrally molded, seam-free reinforcement layers, potentially made through 3D printing or other additive processes, to enhance wall thickness and cross-section in highly loaded areas, allowing for a lighter yet stronger design with organic and bionic contouring that adapts to force flows without overdimensioning in less loaded regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural-frame components are designed for the highest loads by adding safety measures, then safety-reliable strength is improved, but component weight increases due to overdimensioning in less loaded portions
Solution Approach 1:
The patent applies local quality by providing reinforcement layers only in specific highly loaded regions of the structural frame (such as around connection points and in truss joints), while leaving less loaded portions as lightweight hollow profiles. This localized reinforcement approach ensures safety-reliable strength where needed without causing overdimensioning throughout the entire structure, thereby reducing overall component weight.
Solution Approach 2:
The patent uses composite construction by combining hollow profile structural elements with added reinforcement layers in key areas. The reinforcement layers are integrally connected to the hollow profile to form a composite structure that provides enhanced strength and buckling resistance in highly loaded regions while maintaining the lightweight advantage of the hollow profile in less loaded areas.
2Weight of moving object
If structural-frame elements are dimensioned differently in different regions to reduce weight, then component weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the reinforcement layers with the hollow profile structural elements by integrally connecting them during the manufacturing process. This integration ensures that the variable cross-section design (lightweight in less loaded areas, reinforced in highly loaded areas) is achieved as a single unified structure, simplifying manufacturing compared to assembling separate reinforcement components.
Solution Approach 2:
The patent applies parameter changes by varying the wall thickness and cross-sectional dimensions of the structural frame elements along their length. The hollow profile has different wall thicknesses at different locations, with thicker sections in highly loaded regions and thinner sections in less loaded regions, allowing weight optimization while maintaining manufacturability through controlled parameter variation.
3Weight of moving object
If hollow profile struts are used to achieve high flexural rigidity and buckling resistance, then weight is reduced, but strength may be insufficient in highly loaded portions
Solution Approach 1:
The patent applies local quality by providing reinforcement layers only in specific highly loaded regions of the structural frame (such as around connection points and in truss joints), while leaving less loaded portions as lightweight hollow profiles. This localized reinforcement approach ensures safety-reliable strength where needed without causing overdimensioning throughout the entire structure, thereby reducing overall component weight.
Solution Approach 2:
The patent uses composite construction by combining hollow profile structural elements with added reinforcement layers in key areas. The reinforcement layers are integrally connected to the hollow profile to form a composite structure that provides enhanced strength and buckling resistance in highly loaded regions while maintaining the lightweight advantage of the hollow profile in less loaded areas.
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 a lighter component with sufficient strength by targeted reinforcement, achieving excellent force adaptation and preventing overdimensioning in less loaded areas, thus optimizing the structural frame's design for both weight and strength.
Implementation Method 1
This reinforcement portion formed by layer manufacturing may in particular be manufactured by means of 3D printing or stereolithography
Implementation Method 2
provide the structural-frame strut with integrally molded-on, seam-free reinforcement layers in the required, highly loaded region, in order to achieve an organically produced increase in wall thickness and/or cross section
Data Source
AI summary
The present invention relates to a structural frame of a crane, lifting device, material handler or a similar machine, comprising at least one elongate structural-frame strut. The invention also relates to such a machine comprising such a structural frame. According to a first aspect, it is proposed not to weld or screw a separate doubled panel or separate retaining lugs to the structural-frame element as a reinforcement, but rather to provide the structural-frame strut with integrally formed, seam-free reinforcement layers in the required, highly loaded region, in order to achieve an organically produced increase in wall thickness and/or cross section in a smooth and harmonious manner. These reinforcement layers are produced using 3D printing.