End Cap System With Visual Angle Indicator For Spreader Bar Rigging
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Solution Overview
Problem
Current spreader bar systems require precise alignment and physical alteration of tubulars for end cap attachment, leading to increased stress and risk of lift failure due to time-consuming and error-prone selection processes for properly rated and sized end caps.
Innovation Solution
The end cap system includes reinforced apertures and alignment references to ensure proper alignment and secure attachment without altering the tubular, using pre-calculated tolerances and angle indicators to simplify the selection and attachment process, allowing for quick and reliable rigging of lifting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If end caps are attached to spreader bars using spot welds or attachment holes, then the end cap can be securely fixed, but the spreader bar's tolerance for metallurgical stresses is weakened
Solution Approach 1:
The patent introduces an intermediary component (the end cap with internal threading) that interfaces with the spreader bar through a threaded hole rather than requiring spot welds or attachment holes in the tubular portion. This intermediary approach allows secure attachment while avoiding direct metallurgical alteration of the spreader bar's load-bearing structure.
Solution Approach 2:
The attachment system is segmented into separate functional components: the end cap (with threading and orifices), the spreader bar (tubular portion), and the lifting mechanism. This segmentation allows the end cap to bear the attachment functions while the spreader bar maintains its structural integrity for stress tolerance.
2Adaptability or versatility
If workers manually calculate and select the correct end cap fitting for use with a given load and span, then customization is possible, but the process is time-consuming and error-prone
Solution Approach 1:
The patent incorporates pre-calculated tolerance values and sizing guidelines directly into the end cap system documentation and design. This preliminary action of pre-determining correct fittings based on load and span calculations eliminates the need for workers to perform complex manual calculations in the field, reducing time and errors while maintaining adaptability.
3Manufacturing precision
If precise alignment of the end cap with the spreader bar is required, then the attachment is secure, but the assembly process becomes more difficult
Solution Approach 1:
The end cap incorporates asymmetric alignment features such as alignment ribs, positioning keys, or offset orifice arrangements that provide tactile and visual cues for proper orientation. These asymmetric features guide the assembly process, ensuring precise alignment while making the operation simpler through self-alignment rather than requiring complex alignment procedures.
Data Source
AI summary
Several embodiments of an end cap are provided for use with a spreader bar system for distributing the lift force of a load across multiple points. The end cap includes a receptacle shaped to receive the spreader bar. The receptacle comprises an outer end and a pinch bolt located on an outer surface of the receptacle. A load plate abuts the outer end of the receptacle, and is reinforced by a brace. A lifting lug extends from the load plate and has at least a first aperture. The aperture is shaped to receive a corresponding shackle that is configured to connect to a sling for lifting the spreader bar. A visual indicator on a surface of the lifting lug and positioned between the first aperture and the load plate defines a predetermined minimum angle between the spreader bar and the sling when the spreader bar is lifted via the sling.