Deforming Connector Components for Truss Assembly
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Solution Overview
Problem
Existing methods for assembling support structures for passenger transport systems, such as escalators and moving walkways, are inefficient due to the need for welding, which requires skilled labor, is time-consuming, and results in high costs and potential distortion, while alternative methods like screwable nodes are complex and prone to safety risks.
Innovation Solution
A method using load-bearing connector components that deform to fill connection openings completely without play, providing a precise and stable connection between truss components, allowing for assembly on-site without welding, using high-strength blind rivet bolts or expanding sleeves for secure and precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect truss components, then the connection strength is sufficient, but the assembly process becomes time-consuming and requires skilled labor
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical connector system consisting of connector components that insert into connection openings and are deformed to create form-fitting connections. This substitution eliminates the need for skilled welders and reduces assembly time while maintaining connection strength through mechanical interlocking and deformation-based securing.
2Strength
If welding is used to connect truss components, then the connection strength is sufficient, but the cost increases due to skilled labor requirements
Solution Approach 1:
The patent substitutes welding operations with mechanical connector insertion and deformation processes that can be performed by less specialized labor. The connector components are designed to be installed through simple insertion followed by deformation (e.g., expanding, bending, or locking mechanisms), significantly reducing labor costs while maintaining adequate connection strength for the application.
3Strength
If welding is used to connect truss components, then the connection strength is sufficient, but distortion occurs during the assembly process
Solution Approach 1:
The patent replaces welding-induced thermal distortion with a cold-formed mechanical connection process. The connector components are deformed after insertion to create secure connections without generating the intense localized heat that causes truss component distortion. This maintains manufacturing precision and structural integrity while achieving sufficient connection strength through mechanical means.
4Ease of manufacture
If screwable nodes are used instead of welding, then the assembly process becomes simpler, but safety risks increase
Solution Approach 1:
The patent introduces connector components as intermediary elements that provide enhanced safety compared to direct screwable node connections. These connectors include deformation mechanisms (such as expanding sleeves, bent locking tabs, or threaded engagement features) that create secure, load-bearing connections. The intermediary connector acts as a safety-enhancing element that maintains assembly simplicity while eliminating the safety risks associated with conventional screwable nodes.
5Productivity
If truss components are pre-assembled as complete units, then the on-site assembly is faster, but the logistical costs and complexity increase
Solution Approach 1:
The patent divides the truss structure into modular truss components that can be transported separately and quickly assembled on-site using the connector component system. This segmentation allows for optimized transportation (smaller, more manageable pieces) while maintaining fast assembly through the simple connector insertion and deformation process. The modular approach reduces logistical complexity compared to transporting and handling large pre-assembled units.
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
Enables efficient, precise, and cost-effective assembly of support structures with reduced labor requirements, minimizing distortion and safety risks, and allowing for on-site construction with high manufacturing tolerances, thus reducing logistical and operational costs.
Implementation Method 1
The connector components are deformed with regard to their outer geometry in each case in such a way that after the truss components have been connected they completely fill the connection openings through which they pass
Data Source
Figure 1
Figure 2a~2c
Figure 2d~2e
AI summary
The invention relates to a method for installing a support structure (1) for a passenger transport system in a construction. According to the invention, the support structure (1) comprises a framework (3) made of load-bearing framework components (5) connected to each other, including top chords (7), bottom chords (9), cross members (11), diagonal members (13) and vertical supports (15). The method according to the invention comprises: placing a plurality of individual framework components (5), having connection openings (39) designed therein, at an installation position within the construction; and assembling the framework (3) on or near the installation position within the construction by connecting the framework components (5) to each other by means of load-bearing connector components (27), in that a respective connector component (27) is arranged to reach through adjacently arranged connection openings (39) of at least two adjacent framework components (5) and is then deformed in respect of the outside geometry thereof. According to the invention, the connector components (27) are designed and are deformed upon connecting framework components (5) such that they completely fill out the connection openings (39) they reach through, without play, after connection of the framework components (5), and the framework components (5) connect to each other in an interlocking manner in all spatial directions and position the framework components (5) relative to each other when connecting the framework components (5). The assembled framework is then installed in prepared installation locations of the building, within the building. Due to the use of special load-bearing and position-adjusting connector components (27), the described support structure (1) can be assembled very easily and with high precision, including by workers without special certification, and preferably directly adjacent to an installation location within a construction. According to the invention, planning, transport and work costs are thereby reduced.