Hybrid Ceiling Strand Prefabrication Using Modular Webs
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Solution Overview
Problem
Existing methods for constructing structural ceilings in wooden frame houses are laborious, require skilled workers, and involve long prefabrication times and difficult assembly processes, especially when using single wooden strands or large prefabricated panel elements, which necessitate heavy equipment and prolonged on-site construction.
Innovation Solution
A semi-automatic method for hybrid structural ceiling strand prefabrication using cuboid supporting and middle posts, with flattened cuboids and discontinuous webs, connected in a U-shape, allowing for efficient production line assembly and storage, reducing the need for heavy equipment and shortening assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single wooden strands are used for structural ceilings, then the construction can be done with simple materials, but the assembly process becomes laborious and requires skilled workers
Solution Approach 1:
The ceiling structure is divided into modular strand elements with standardized connections. Each strand consists of discrete wooden components (flattened cuboids, webs, straps) that can be independently manufactured and then assembled through simple connection points, eliminating the need for skilled workers to perform complex carpentry on-site.
Solution Approach 2:
The strand elements are pre-assembled and pre-positioned in the factory with all necessary connections prepared in advance. This preliminary assembly includes pre-drilled holes, pre-applied connectors, and pre-configured geometries, so that on-site installation only requires simple placement and connection without requiring skilled manual assembly operations.
2Productivity
If large prefabricated panel elements are used, then assembly can be standardized, but heavy equipment is required for transport and assembly
Solution Approach 1:
The ceiling structure is divided into smaller modular strand elements rather than large monolithic panels. Each element contains discrete components (webs, straps, cuboids) that can be transported separately using lighter equipment, yet still achieve high assembly productivity through standardized connection systems that enable rapid on-site assembly.
3Ease of manufacture
If traditional wooden strand methods are used, then material simplicity is maintained, but prefabrication time is prolonged
Solution Approach 1:
All preparatory operations including cutting, shaping, drilling, and connection preparation are performed in advance in the factory setting. The strand elements arrive on-site with all necessary features already configured, eliminating time-consuming on-site fabrication and significantly reducing the overall prefabrication timeline while maintaining material simplicity.
Solution Approach 2:
Traditional manual or slow mechanical woodworking operations are replaced with automated factory equipment for cutting, shaping, and assembling the wooden components. This substitution of manual mechanical processes with automated manufacturing systems dramatically accelerates the prefabrication process while maintaining the simplicity of wooden materials.
4Adaptability or versatility
If on-site assembly of structural ceilings is performed, then flexibility is maintained, but the process becomes laborious and time-consuming
Solution Approach 1:
The ceiling system is segmented into modular strand elements that can be independently manufactured and assembled. This segmentation provides adaptability for different ceiling configurations and spans while enabling high productivity through standardized connection systems that allow rapid assembly of the modular components on-site without laborious custom fabrication.
Data Source
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AI summary
The object of the invention is the method of hybrid structural ceiling strand prefabrication characterized in that: a) in the first process, with the use of feeding conveyors elements in the form of flattened cuboids are delivered to the crosscut saw 7, where the crosscuts are made in order to receive the upper straps 20 and the lower strap 21, b) in the second process with the use of CNC plotter 9 two identical rectangular webs 22 are cut, where each web has at least two straps, and in between, in the symmetry axis of each web is at least one technological hole 23, next milling of the webs' surfaces is carried out, c) next in the assembly area 1, one by one, the following technological processes are carried out: - the lower strap 21 is placed at its cradle 14 and stabilized, - on the lower strap 21, the rectangular support 24 and middle 25 posts are placed, and the lower surface of the supports adhering the lower strap is covered with layer of the glue, - one upper strap 20 of the strand is placed on each of rotating side arms 19, - on each end of each upper strap 20 of the strand, one the rectangular support posts is placed, and the lower surface of the supports is covered with layer of the glue, - on the side surface of each upper strap 20 and attached support posts 24, after placing layer of the glue, webs 22 are placed, - the cradle 14 together with the attached lower strap 21 of the strand is rotated by 90°, - the milled surfaces of the web 22, which are placed on the right side rotating arm 19, are covered with glue, - the right side arm 19 is rotated by 180° in such way, that attached right side wing almost overlaps the lower strap 21, - the right side wing is glued and stapled to the elements of the lower strap 21, - the right side rotating arm 19 returns to the initial position, - the cradle 14 together with the attached lower strap 21 is rotated by 180°, - the milled surfaces of the web 22, which are placed on the left side rotating arm 19, are covered with glue, - the left side arm 19 is rotated by 180° in such way, that attached left side wing almost overlaps the lower strap 21, - the left side wing is glued and stapled to the elements of the lower strap 21, which are placed on the cradle 14, - the left side rotating arm 19 returns to the initial position, - the cradle 14 of the lower strap 21 of the strand returns to the initial position, - the end 15 and side 16 pneumatic actuators are released, - the ready hybrid strand is removed with the vacuum manipulator 11 and placed in the storage area 13.