Deployable Production Facility for Modular Building Construction

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Solution Overview

Problem

Residential building construction is inefficient and costly due to the high expenses of permanent production facilities, substantial transportation costs for modular building modules, and the lack of coordination between projects, leading to delays and increased competition for resources.

Innovation Solution

A deployable production facility that includes a frame supporting overhead cranes and a tent, allowing for the production of building modules on-site and enabling easy redeployment to different locations, thereby minimizing transportation costs and optimizing resource utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a permanent production facility is built to produce building modules, then manufacturing precision and productivity are improved, but capital costs and device complexity increase significantly

Engineering Contradiction:

Improvebuilding module production efficiencyVSAvoidproduction facility complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The production facility is divided into modular components that can be segmented and reconfigured. The facility uses modular building modules as both the product and the structural components of the facility itself, allowing the system to be broken into discrete, movable units that can be assembled and disassembled as needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The production facility transitions from a static permanent structure to a dynamic, movable system. The entire facility can be disassembled, transported, and reassembled at different locations, allowing the production capacity to move with the project rather than remaining fixed.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If building modules are transported from a permanent production facility, then manufacturing precision is improved, but transportation costs increase substantially

Engineering Contradiction:

Improvebuilding module construction qualityVSAvoidtransportation costs

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The production facility is positioned at the same location as the building project, eliminating the need for long-distance transportation. By making the production site and construction site the same location, the system removes the transportation step entirely, making the energy expenditure for transport zero.

Inventive Principle:

Principle #12Equipotentiality

3Productivity

If a large permanent production facility is built to serve multiple customers, then productivity is improved, but capital costs increase and competition for resources intensifies

Engineering Contradiction:

Improvebuilding module output volumeVSAvoidfacility relocation flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The facility is designed to be movable and reconfigurable rather than fixed. This allows the same high-capacity production facility to be relocated to different project sites, serving multiple customers sequentially rather than requiring multiple fixed facilities simultaneously, thereby reducing overall capital requirements.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The production facility serves multiple functions and multiple customers over time through relocation. The same facility infrastructure can be deployed for different building projects at different locations, maximizing utilization and reducing the need for duplicate facilities for each customer.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If traditional on-site construction is used, then adaptability to site conditions is maintained, but construction time and costs increase due to inefficiency

Engineering Contradiction:

Improvesite condition adaptabilityVSAvoidconstruction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The construction process is segmented into modular building modules that are pre-assembled in the production facility. This allows parallel processing where multiple modules can be prepared simultaneously while site preparation occurs, then quickly assembled on-site, dramatically increasing construction speed while maintaining adaptability through modular design.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11767680B2Deployable manufacturing production facility and method

Publication Date: 2023.09.26 VAN KLEEF ERICUS ANDREAS

AI summary

A deployable production facility may be used to produce building modules for use in the construction of buildings, and may be capable of later being redeployed at other locations. A frame is removably mounted to a production floor and is used to support one or more overhead cranes that are positioned over one or more production lines defined on the production floor, and a tent, is used to enclose the production line(s), frame and overhead cranes. As desired, the tent, overhead cranes and frame may be disassembled and redeployed at a different site.