Floor Decking Cart with Peak-Contact Wheel Array
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Solution Overview
Problem
Current deck processing procedures are inefficient and unsafe, as they require workers to manually transport and position floor decking, weld studs while bent over, and conduct quality control tests, leading to physical strain, potential contamination, and inaccurate weld parameter analysis.
Innovation Solution
A system of carts with wheel assemblies that uniformly traverse floor decking, allowing workers to remain standing while depositing deck material, welding studs, and analyzing weld parameters in real-time, reducing the need for puddle welding and improving ergonomics and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If workers manually transport and position floor decking, then flexibility and adaptability are maintained, but physical strain and safety risks increase
Solution Approach 1:
A cart system serves as an intermediary device between workers and floor decking materials. The cart has a platform for holding decking bundles and is equipped with wheels that navigate the corrugated deck surface. This intermediary tool bears the weight and handling burden, freeing workers from direct manual manipulation while maintaining operational flexibility.
Solution Approach 2:
The cart system is designed to be self-propelled or easily movable by workers through simple manual effort. The cart's weight distribution and wheel configuration enable it to roll smoothly over the corrugated deck without requiring workers to lift heavy decking bundles, thus the system serves itself in transporting materials while minimizing worker physical strain.
2Ease of operation
If workers weld studs while bent over, then access to weld locations is achieved, but physical strain and injury risk increase
Solution Approach 1:
The welding system is repositioned from a ground-based handheld tool to an overhead suspended configuration. The welding apparatus hangs from above, allowing workers to stand upright and simply guide the welding tool downward to the work location. This dimensional change in tool positioning eliminates the need for workers to bend over, maintaining weld quality while improving ergonomics and safety.
3Ease of manufacture
If puddle welding is used to attach metal deck to beams, then initial deck securing is achieved, but weld contamination and quality control issues arise
Solution Approach 1:
The system performs preliminary cleaning of the beam surface and precise positioning of the metal deck before welding occurs. By preparing the weld area in advance and ensuring proper alignment, the need for corrective puddle welding is eliminated. This preliminary preparation prevents contamination issues before they arise, allowing for cleaner, higher quality welds on the first attempt.
4Reliability
If workers use extension hoses to limit cart movement, then cylinder stability is improved, but cost and complexity increase
Solution Approach 1:
The cart's wheel configuration and platform design create a stable, balanced system that naturally resists movement and maintains cylinder stability without requiring additional stabilizing equipment. The weight distribution and wheel placement are optimized so the cart remains steady during operation, achieving the same effect as extension hoses but through inherent design rather than added complexity.
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
The system enhances safety and efficiency by allowing workers to perform tasks while standing, reduces physical strain, and provides immediate, scientific quality control of welds, thereby improving the quality and reducing the need for costly extensions and minimizing contamination risks.
Implementation Method 1
The wheel assembly has an array of wheels forming a predetermined pattern of wheels positioned under the cart wherein at any given instant of time a number of the wheels contact peaks of the floor decking
Implementation Method 2
welds the studs onto bare beams or through the deck material to the beam
Implementation Method 3
scientifically analyzes weld parameters, such as time, current, lift and plunge, used during the stud weld process
Data Source
AI summary
A cart that uniformly transverses floor decking that has sequential peaks and valleys. The cart comprises a wheel assembly having an array of wheels forming rows and columns of wheels positioned under the cart wherein at any given instant of time a number of the wheels of the rows and columns contact peaks of the floor decking and while other wheels extend over and free from contacting the valleys such that the cart uniformly traverses the floor decking.