Modular Arch Former Segmentation for Flat-Pack Transport
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Solution Overview
Problem
Existing arch formers for masonry arches are costly to manufacture and transport due to the need for various molds and tools, and are wasteful of materials, as they are typically fully fabricated before shipping and have a low size-to-weight ratio.
Innovation Solution
An arch former comprising a planar elongate base with longitudinally extending grooves and apertures, side panels with straight and curved edges, and a top section with locking means, allowing for easy assembly and disassembly, reducing the need for multiple molds and enabling efficient storage and transport in a disassembled 'flat-pack' configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If arch formers are fully fabricated prior to shipping, then structural integrity is ensured, but storage and transportation costs increase due to low size-to-weight ratio
Solution Approach 1:
The arch former is divided into multiple separable components including a base component, side components, and a top component. These components can be stored and transported independently in a compact configuration, then assembled on-site to form the complete arch former structure, thereby reducing storage space requirements while maintaining structural integrity when assembled.
Solution Approach 2:
The side components are designed to nest within or alongside each other and the base component when disassembled. The top component can be positioned within the assembled side components, creating a compact nested configuration that minimizes storage volume and transportation space while preserving the structural integrity of the complete assembly.
2Stability of the object's composition
If arch formers are fully fabricated prior to shipping, then structural integrity is ensured, but manufacturing costs increase due to processing and assembly requirements
Solution Approach 1:
The arch former is segmented into modular components that can be manufactured using standardized processes. The base component, side components, and top component can each be produced independently using similar manufacturing methods, reducing the need for specialized tooling and molds for different arch dimensions, thereby lowering manufacturing costs while ensuring structural integrity through standardized connection mechanisms.
Solution Approach 2:
The modular components are designed with universal features such as standardized connection elements and adaptable geometries that allow the same basic components to be used for different arch sizes and configurations. This universality reduces the variety of molds and tools required during manufacturing, decreasing production costs while maintaining the structural integrity needed for various applications.
3Manufacturing precision
If arch formers are made from extruded sections and machined to size, then manufacturing precision is achieved, but material waste increases and production time is extended
Solution Approach 1:
The base component, side components, and top component are designed to be extruded or formed to their final dimensions directly during the manufacturing process, eliminating the need for subsequent machining operations. This preliminary action achieves the required dimensional accuracy through precision extrusion tooling while minimizing material waste by forming components to near-net shape.
Solution Approach 2:
The manufacturing approach transitions from machining (subtractive process) to extrusion or forming (formative process). This parameter change in the manufacturing method allows components to be produced with high dimensional accuracy directly from the shaping process, significantly reducing material waste compared to traditional machining from extruded sections.
4Adaptability or versatility
If different arch dimensions are manufactured using various molds and tools, then dimensional versatility is achieved, but manufacturing cost increases
Solution Approach 1:
The arch former is segmented into modular components with standardized connection interfaces. Different arch dimensions can be achieved by varying the dimensions of individual modules (base, sides, top) while maintaining the same connection mechanisms. This segmentation allows dimensional versatility without requiring different molds and tools for each configuration, as the same basic tooling can produce components in various sizes.
Solution Approach 2:
The modular components are designed with universal connection features and standardized interfaces that work across different arch configurations. This universality allows a single set of manufacturing tools and molds to produce components for multiple arch dimensions and styles, achieving dimensional versatility while reducing manufacturing costs by eliminating the need for specialized tooling for each variant.
Data Source
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AI summary
An arch former comprising: a planar elongate base (2), having two longitudinally extending grooves (12A, 12B) spaced apart, and at least one aperture (14A, 14B) arranged at each end; two side panels (4A, 4B), wherein each side panel (4A, 4B) comprises a straight bottom edge (8A, 8B) and a curved top edge (10A, 10B); and a top section (6), formed as an elongate panel arranged to extend over the curved top edges of the side panels (4A, 4B) and comprising a locking means disposed at each end arranged to cooperate with the at least one aperture (14A, 14B) arranged at each end of the base (2), and two longitudinally extending grooves (18A, 18B) spaced apart; wherein each groove (12A, 12B) of the base (2) is configured to receive at least a portion of the bottom edge (8A, 8B) of one of the side panels (4A, 4B), and wherein each groove (18A, 18B) of the top section (6) is arranged to receive at least a portion of the top edge (10A, 10B) of one of the side panels (4A, 4B).