Mandrel Ball Joint for Duct Orientation in Concrete
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Solution Overview
Problem
In precast concrete segmental construction, existing couplers struggle to maintain a liquid-tight seal between ducts due to misalignment and warping of concrete segments, leading to potential corrosion of post-tensioning cables and structural integrity issues, especially when ducts extend at angles relative to the concrete edges.
Innovation Solution
A mandrel system with an angle adjusting mechanism, including a pin, ball, and flange, allows for precise orientation of ducts at desired angles, combined with flexible boots and clamping mechanisms to ensure liquid-tight seals and accommodate misalignments, using a U-shaped frame and ball joint to connect the ducts to a bulkhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing couplers are used to join ducts, then the ducts can be connected, but misalignment and warping of concrete segments cause loss of liquid-tight seal
Solution Approach 1:
The coupler incorporates a ball joint mechanism that allows dynamic adjustment of the duct orientation to accommodate misalignment and warping in the concrete segments. The ball joint enables the coupler to adapt to varying angles while maintaining a secure connection, resolving the contradiction between maintaining a liquid-tight seal and dealing with manufacturing imprecision in duct alignment.
Solution Approach 2:
The coupler design allows for changing the angular parameter of the duct connection through the ball joint mechanism. This enables the system to adjust to different alignment conditions caused by concrete segment warping, thereby maintaining the liquid-tight seal despite variations in manufacturing precision.
2Manufacturing precision
If rigid couplers are used to maintain precise orientation, then alignment is improved, but adaptability to misalignment and warping is reduced
Solution Approach 1:
The ball joint mechanism transforms the rigid coupler into a dynamic system that can adjust its orientation. This allows the coupler to maintain precise duct orientation when needed while simultaneously adapting to misalignment and warping in the concrete segments, resolving the contradiction between precision and adaptability.
Solution Approach 2:
The coupler is divided into multiple functional segments including the ball joint component and the clamping mechanism. This segmentation allows different parts to perform specialized functions: the ball joint handles orientation adjustment while the clamping mechanism ensures secure attachment, enabling both precision and adaptability.
3Adaptability or versatility
If adjustable angle mechanisms are added to accommodate misalignment, then adaptability is improved, but device complexity increases
Solution Approach 1:
The ball joint provides an elegant dynamic solution that achieves angle adjustment capability with relatively simple mechanics. The spherical interface naturally accommodates angular variations without requiring complex multi-component adjustment mechanisms, thus improving adaptability while minimizing the increase in device 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 effectively maintains a liquid-tight seal between ducts, prevents epoxy intrusion, and ensures consistent duct orientation, enhancing the structural integrity and durability of precast concrete segmental structures by accommodating angled ducts and misalignments.
Implementation Method 1
The angle adjusting means includes a pin extending through the frame, a ball mounted on the pin, and a flange affixed to the ball. The flange is in surface-to-surface contact with an end of the elongated body. The pin is operably connected to the ball so as to fix an orientation of the flange.
Data Source
AI summary
An apparatus for fixing an orientation of a duct in concrete segmental construction has an elongated body, a frame having an inner surface facing the elongated body, and an angle adjusting means connecting the inner surface of the frame to the elongated body. The elongated body is orientable relative to the frame about the ball joint. The angle adjusting means includes a pin extending through the frame, a ball mounted on the pin, and a flange mounted to the ball so as to be in surface-to-surface contact with an end of the elongated body. The pin is operably connected to the ball so as to fix an orientation of the flange.