Modular Chocking Compound Dam Assembly for Faster Engine Footing Installation
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Solution Overview
Problem
The legacy method of forming chocking compound dams for engine footings is time-consuming, costly, and has a high failure rate, requiring manual construction and taking an average of a full day with a 40%-50% failure rate, leading to additional time and material costs.
Innovation Solution
A custom tool designed for additive manufacturing, specifically 3D printed using Fused Filament Fabrication, allows for rapid creation of modular chocking compound dam assemblies with prefabricated walls and interlocking mechanisms, reducing installation time to about 1 hour and improving structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual construction of dams is used, then flexibility in dam shape can be achieved, but installation time increases to an average of a full day
Solution Approach 1:
The dam is divided into multiple modular segments that can be quickly assembled on-site. Each segment is pre-fabricated with standardized connection interfaces, allowing rapid assembly while maintaining the ability to create various dam shapes by combining different segments in different configurations.
2Adaptability or versatility
If manual construction of dams is used, then on-site customization is possible, but failure rate increases to 40%-50%
Solution Approach 1:
Critical dam components and connection mechanisms are pre-tested and pre-assembled in controlled manufacturing environments before deployment. This preliminary action ensures proper fit and function, reducing on-site construction errors and increasing overall reliability while still allowing customization through modular assembly.
3Ease of manufacture
If legacy materials (wood, sheet metal, putty) are used for dams, then material availability is high, but structural integrity and watertightness are insufficient
Solution Approach 1:
The dam structure uses composite construction combining rigid structural elements (for strength and shape) with flexible sealing materials (for watertightness). This composite approach maintains ease of manufacture using commonly available materials while achieving superior structural integrity and sealing performance that legacy single-material dams could not provide.
4Adaptability or versatility
If custom dams are fabricated for each application, then geometric requirements are met, but manufacturing complexity and cost increase
Solution Approach 1:
The dam system employs universal modular segments with standardized connection interfaces that can be configured to meet various geometric requirements. This universality reduces manufacturing complexity by using the same basic components across different applications while maintaining the ability to adapt to specific geometric needs through different assembly configurations.
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 new dam system significantly reduces installation time, lowers re-work and overhead costs, and ensures a superior, uniform foundation with a lower failure rate, enabling reuse of some components and adaptable to various geometric requirements.
Implementation Method 1
It was specifically designed to be 3D printed and take advantage of the Fused Filament Fabrication printing process
Implementation Method 2
Chockfast is a two-part inert chocking or grouting compound for use under machinery, it is poured as a liquid and then exothermically cures filling the created dam/void
Data Source
AI summary
In an example, a chocking compound dam includes a plurality of prefabricated dam walls. Each prefabricated dam wall has two side edges each being configured to connect to a side edge of another prefabricated dam wall. The plurality of prefabricated dam walls are connected to form a dam surrounding a chocking compound pour area. Each prefabricated dam wall has a height and a length. At least one of the prefabricated dam walls includes a longitudinal stiffener. The longitudinal stiffener extends along the length of the prefabricated dam wall and has a width protruding transversely from the prefabricated dam wall.