Modular Construction Elements With Cut-Outs For Rapid Assembly
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Solution Overview
Problem
Current modular construction systems for knockdown structures face challenges in achieving short construction and knockdown times while maintaining high structural strength and flexibility in configuration, leading to increased labor and opportunity costs.
Innovation Solution
A modular construction system comprising elongate construction elements with specific hole configurations and cut-outs for bolt insertion, allowing for high bending and shear capacity joints, and adaptable jointing elements that enable various structural configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional modular construction systems are used, then construction and knockdown times are reduced, but structural strength and configuration flexibility are compromised
Solution Approach 1:
The construction element is segmented into distinct functional components: an elongate body for structural continuity, end plates for connection interfaces, and specifically positioned holes with cut-outs for fastener accommodation. This segmentation allows each component to be optimized independently while maintaining overall structural integrity during rapid assembly
Solution Approach 2:
The cut-outs are pre-formed in the web at specific positions corresponding to the holes in the end plates. This preliminary preparation of the fastener path eliminates the need for drilling or complex alignment during assembly, enabling quick construction while maintaining precise hole alignment for optimal structural strength
2Loss of time
If conventional modular construction systems are used, then construction and knockdown times are reduced, but configuration flexibility is compromised
Solution Approach 1:
The construction element design with standardized end plates containing multiple holes and corresponding cut-outs serves multiple functions: it enables connections at various positions, accommodates different fastener types, and allows both rigid and flexible joint configurations. This universal design permits the same element to be used in diverse structural arrangements without requiring custom modifications
Solution Approach 2:
The system allows dynamic reconfiguration by enabling elements to be connected in various orientations and positions. The cut-out positions and hole arrangements permit adjustment of connection points along the element length, allowing the structure to be dynamically adapted to different spatial requirements while maintaining rapid assembly capability
3Strength
If complex jointing systems are used to achieve high bending and shear capacity, then structural strength is improved, but construction time and device complexity increase
Solution Approach 1:
The fastener accommodation function is extracted from the end plate holes and implemented separately through cut-outs in the web. This extraction simplifies the end plate design to a straightforward connection interface while the cut-outs provide the mechanical guidance and support needed for high-strength fastener connections, separating the connection function from the structural member
4Strength
If multiple holes are provided in end plates for high capacity joints, then bending and shear capacity are improved, but manufacturing complexity and fastener installation time increase
Solution Approach 1:
The manufacturing of holes and cut-outs is merged into a single integrated process step. The cut-outs are formed as continuous features extending from the end plate through the web, combining what would otherwise be separate drilling and cutting operations. This merging simplifies manufacturing while ensuring precise positioning of multiple fastener paths for high-capacity joints
Data Source
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AI summary
A modular construction system includes an elongate construction element (10) with an elongate body (12) including a longitudinal web (14), opposite first and second edges (16.1, 16.2) a longitudinal first flange (18.1) transverse to the web (14) along the first edge (16.1), opposite first and second ends (20.1, 20.2), a first end plate (24.1) orthogonal to the to the web (14) with a first hole (26), a second hole (30) intermediate the first hole and the first edge, a third hole intermediate the first hole and the second edge. For each of the holes, a cut-out (28, 32, 36) is provided in the web.