Escalator Modular Truss Cold Joining Eliminates Weld Deformation

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Solution Overview

Problem

Current escalator and moving walkway modular trusses face issues with deformations due to welding, requiring time-consuming and expensive assembly processes, generating hazardous environments, and consuming high energy, while also lacking precise dimensional control and requiring skilled operators.

Innovation Solution

The modular truss system uses cold joining technology with custom-made cold rolled steel profiles and integrated vertical and diagonal beams to support guiding systems and balustrades, eliminating the need for welding and allowing for precise assembly through automated processes, reducing energy consumption and environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to assemble modular trusses, then structural strength is improved, but manufacturing precision deteriorates due to thermal stresses and deformations

Engineering Contradiction:

Improvestructural strengthVSAvoidtruss dimensional accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent changes the fundamental parameter of the joining process from thermal (welding) to mechanical (cold-rolling). This eliminates thermal stresses that cause deformation while maintaining structural integrity through cold-formed connections between steel profiles and aluminum supports.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the welding mechanical system with a cold-rolling mechanical system. The cold-rolling process uses mechanical pressure to form precise connections without generating thermal energy, thereby avoiding the thermal deformations that compromise manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If welding is used to assemble modular trusses, then structural integrity is improved, but assembly time increases due to straightening requirements

Engineering Contradiction:

Improvetruss structural integrityVSAvoidassembly time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The patent performs preliminary cold-rolling of the steel profiles and pre-assembly of aluminum supports to exact dimensions before final assembly. This preliminary precision work eliminates the need for post-assembly straightening operations, significantly reducing total assembly time while maintaining structural integrity.

Inventive Principle:

Principle #10Preliminary action

3Strength

If welding is used to assemble modular trusses, then structural strength is improved, but energy consumption increases

Engineering Contradiction:

Improvetruss strengthVSAvoidwelding energy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent substitutes the high-energy welding process with a low-energy cold-rolling mechanical process. The cold-rolling operation uses only mechanical pressure to form connections, eliminating the substantial electrical energy consumption required for welding operations while achieving equivalent or superior connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If welding is used to assemble modular trusses, then structural connection is improved, but harmful factors increase due to sparks and fumes

Engineering Contradiction:

Improveconnection strengthVSAvoidsparks and fumes

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the welding mechanical system that generates harmful sparks and fumes with a cold-rolling mechanical system. The cold-rolling process uses only mechanical deformation to create connections, completely eliminating the combustion-related harmful emissions and sparks associated with welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Stability of the object's composition

If welding is used to assemble modular trusses, then structural integrity is improved, but operator skill requirements increase

Engineering Contradiction:

Improvetruss integrityVSAvoidassembly complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The patent replaces the complex welding operation requiring highly skilled operators with a simpler cold-rolling mechanical operation. The cold-rolling process is more easily controlled and monitored, reducing the skill level required while maintaining or improving assembly quality through consistent mechanical deformation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution results in a more efficient, cost-effective, and environmentally friendly assembly process with improved dimensional accuracy and reduced assembly time, enhancing the structural integrity and ride quality of escalators and moving walkways by integrating guide supports and balustrades directly into the truss structure.

Implementation Method 1

cold rolled profiles

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

A clinching connection is formed by a male die and a female die using local deformation, and it connects two metal workpieces

Methodology Applied

Scientific EffectLocal deformation: Deformation

Data Source

PatentEP3109195B1Escalator/moving walkway modular truss and method of assembling an escalator/moving walkway modular truss

Publication Date: 2021.09.15 THYSSENKRUPP ELEVATOR INNOVATION CENTER SA

Figure 1
Figure 2a~2b
Figure 2c~2d

AI summary

Escalator/moving walkway modular truss, each module (1,2,3) comprising opposite sides (4,5) including a lower profile (6) and an upper profile (7), and vertical and diagonal beams (9,10) placed between them. The lower profiles (6) support directly an outer cladding of the escalator/moving walkway, and the upper profiles (7) support directly balustrades (12) and outer decking profiles (13) of the escalator/moving walkway. Additionally, the invention relates to a method of assembling an escalator/moving walkway modular truss, including the cold rolling of the profiles (6,7) and the cold joining of vertical and diagonal beams (9,10) between them.