Irrigation Truss Bracket Assembly With Weld-Free Mechanical Interlocks
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Solution Overview
Problem
Modern irrigation machines face challenges with truss brackets and linking components that require numerous welds, leading to inconsistent quality and potential failure due to defective welds, which are costly and time-consuming to repair in the field.
Innovation Solution
A pipe connection system comprising a truss angle bracket assembly, hitch channel lock assembly, and truss rod bracket assembly, all formed from laser-cut and bent metal pieces to minimize welds and enhance strength, with mechanical interlocks to secure truss rods and other components to the irrigation pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional welding methods are used to assemble truss brackets from multiple stamped components, then the assembly can be manufactured using conventional processes, but the weld quality becomes inconsistent and defective welds can cause immediate failure of the irrigation span
Solution Approach 1:
The patent merges multiple stamped components into a single laser-cut and bent metal piece that forms the complete truss bracket assembly. This eliminates the need for welding multiple components together, thereby resolving the contradiction by maintaining ease of manufacture through conventional laser cutting and bending processes while dramatically improving reliability by eliminating weld quality issues entirely
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical joining method) with mechanical interlocking through laser-cut and bent metal pieces. The bent sections create inherent mechanical locks that secure components together without requiring welds, thus substituting a problematic thermal- mechanical joining system with a reliable mechanical interlocking system
2Ease of manufacture
If numerous welds are used to connect truss bracket components, then the components can be joined together, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent combines multiple components that would require numerous welds into a single integrated laser-cut and bent metal piece. This merging reduces the assembly process to simple mechanical interlocking of pre-formed sections, eliminating complicated welding operations and significantly improving manufacturing productivity
Solution Approach 2:
The patent performs the joining action preliminarily during the laser cutting and bending process itself. The metal piece is cut and bent into its final three-dimensional configuration with built-in interlocking features before assembly, eliminating the need for subsequent welding operations and thereby increasing manufacturing speed
3Ease of repair
If defective welds occur in the field, then repairs are necessary, but the repair process is expensive and time-consuming with inferior quality results due to galvanizing
Solution Approach 1:
The patent extracts the welding process entirely from the truss bracket assembly by using laser-cut and bent metal pieces with mechanical interlocking. This extraction eliminates the source of defective welds that would require field repair, thereby improving reliability by preventing the need for repair while also improving ease of repair since no welding repairs are needed
Solution Approach 2:
The patent employs a design where the entire bracket assembly is manufactured as a single or minimally assembled unit from laser-cut stock material. This approach makes the component itself more replaceable and less prone to field repair needs, effectively treating the bracket as a durable but replaceable unit rather than a complex welded assembly requiring skilled repair
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 solution provides a stronger and more reliable connection that eliminates the need for weld quality control, reducing the risk of failure and simplifying the manufacturing process by minimizing welds and ensuring the irrigation system can withstand significant forces.
Implementation Method 1
a single laser cut piece that is then folded using bending stations
Implementation Method 2
a single laser cut piece that is then folded using bending stations
Data Source
AI summary
An improved pipe connection system for attaching truss rods and other irrigation system components to an irrigation pipe. According to a first preferred embodiment, the attachment system of the present invention preferably includes a truss angle bracket assembly, a hitch channel lock assembly and a truss rod bracket assembly which are designed and positioned to attach to a single pipe section. According to a further preferred embodiment, the truss bracket assembly, the hitch channel lock assembly and the truss rod bracket assembly of the present invention are preferably each formed of single part/die surfaces which are laser-cut and bent on a transfer press to provide multiple sections formed from the single part/die surfaces.