Modular Chocking Compound Dam Walls for Faster Engine Foundation Pouring
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Solution Overview
Problem
The legacy method of forming chocking compound dams for engine foundations 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 3D printed chocking compound dam device designed for rapid installation, using additive manufacturing and modular prefabricated dam walls with interlocking mechanisms, allowing for quick assembly and adaptation to various geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual construction of dams is used, then flexibility in creating custom dam shapes is achieved, but installation time increases to an average of a full day
Solution Approach 1:
The dam is divided into multiple pre-fabricated modular segments that can be quickly assembled on-site. Each segment is manufactured separately using additive manufacturing technology, allowing for rapid production of custom-shaped components that can be easily connected to form the complete dam structure, eliminating the time-consuming manual construction process while maintaining design flexibility.
Solution Approach 2:
The dam segments are pre-fabricated off-site using additive manufacturing technology before being transported to the installation location. This preliminary manufacturing action allows complex custom shapes to be created with high precision in advance, so that only simple assembly operations are required on-site, dramatically reducing installation time from a full day to a fraction of that time.
2Ease of operation
If manual construction of dams is used, then on-site adjustments can be made, but the failure rate increases to 40%-50%
Solution Approach 1:
The manufacturing process parameters are changed from manual construction to additive manufacturing technology. This parameter change enables precise control over the geometric parameters of each dam segment, ensuring consistent quality and dimensional accuracy. The digital modeling and automated manufacturing eliminate human error in construction, reducing the failure rate from 40%-50% to a much lower level while maintaining the ability to make adjustments through digital model modifications.
Solution Approach 2:
The dam design is created as a digital 3D model that can be precisely replicated through additive manufacturing. This digital copying process ensures that each segment is manufactured with exact specifications, eliminating the variability and errors associated with manual construction. The digital model can be easily modified and re-printed if adjustments are needed, providing a reliable and repeatable manufacturing process.
3Strength
If traditional materials like wood and metal are used for dams, then structural strength is achieved, but the complexity of assembly increases
Solution Approach 1:
The dam segments are manufactured using composite materials through additive manufacturing technology. These composite materials provide the necessary structural strength to contain the chocking compound while being formed into integrated, complex geometries that eliminate the need for separate assembly components. The monolithic construction approach reduces assembly complexity compared to traditional wood and metal structures that require multiple pieces and fasteners.
4Productivity
If 3D printed modular dam walls are used, then installation time is reduced to about 2 hours, but manufacturing precision requirements increase
Solution Approach 1:
The mechanical manufacturing processes are replaced with additive manufacturing technology, which uses digital modeling and automated material deposition to create dam segments with high precision. This substitution of manufacturing methodology enables complex geometries to be produced with consistent dimensional accuracy and surface quality, meeting the precision requirements necessary for rapid on-site assembly while maintaining the productivity benefits of pre-fabricated modular components.
Data Source
AI summary
In an example, a kit for a chocking compound dam includes a plurality of prefabricated dam walls and a prefabricated pour spout clip. Each 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 may include 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. The prefabricated pour spout clip may have a lower clip portion connected to an upper pour portion. The lower clip portion is configured to be clipped to an upper edge of a prefabricated dam wall of the prefabricated dam walls.