Flow-Formed Ground Screw Foundation Without Welding
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Solution Overview
Problem
The existing methods for producing ground screw foundations are complex and labor-intensive, requiring shaping and welding of base bodies with conical forms and thread-like contours, which complicates the production process.
Innovation Solution
The method involves forming an inner contour and thread-like contour exclusively through flow forming, allowing for the production of ground screw foundations using a cylindrical tube, which can be elongated and shaped to create a conical front section and thread-like features without welding, thereby simplifying the process and reducing production effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional hammering and welding methods are used to produce ground screw foundations, then the base body can be formed with conical shapes and threaded contours, but the production process becomes complex and labor-intensive
Solution Approach 1:
The patent combines multiple production steps (forming the base body, creating the conical front section, and generating the threaded contour) into a single flow forming operation. This eliminates the need for separate welding operations to attach threads and surface elements, thereby simplifying the production process and reducing labor intensity while maintaining manufacturing capability.
Solution Approach 2:
The flow forming tool is designed to perform multiple functions simultaneously: it forms the overall shape of the base body, creates the conical front section for ground insertion, and generates the threaded contour for securing elements. This multi-functional approach replaces multiple specialized operations (hammering, welding, threading) with a single versatile process, reducing production complexity.
2Productivity
If multiple separate operations (shaping, welding threads, affixing surface elements) are used, then the base body can be produced with required features, but production effort and time increase
Solution Approach 1:
The flow forming process operates continuously to create the entire ground screw foundation in one uninterrupted operation. The tool moves along the tube in a single continuous motion, forming the base body, conical section, and threaded contour without stopping for welding or repositioning. This eliminates idle time between operations and maintains continuous productive action throughout the manufacturing process.
Solution Approach 2:
The tube is prepared in advance as a drawn or welded initial form with the required material properties and basic dimensions. This preliminary preparation allows the flow forming operation to proceed efficiently without needing to create the basic tube structure during the main production process, thereby reducing the total production time while maintaining high productivity in the forming operation itself.
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 approach results in precise, reproducible components with reduced production complexity, enabling efficient and cost-effective manufacturing of ground screw foundations.
Implementation Method 1
a conical front section is formed on the cylindrical tube, by means of a non-cutting process... the front section and the thread-like contour are formed exclusively by means of flow forming
Data Source
AI summary
A method for producing a screw foundation for securing elements in the ground, provides a cylindrical tube as an initial form and a conical front portion tapering to an insertion tip is then molded on to the cylindrical tube using a non-cutting process, the front portion being provided at least in some regions with a thread-like contour for screwing into the ground. An inner contour for a screwing tool is formed integrally in a rear end of the tube by flow forming, and the front portion and the thread-like contour are formed exclusively by flow forming.