Modular Escalator Track Assembly for Precise Alignment in Less Space
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Solution Overview
Problem
Existing escalator assembly processes are inefficient, requiring significant time, effort, and resources due to the need for precise alignment and positioning of components, especially in the construction of load-bearing support structures, which lack standardization and flexibility, leading to high manufacturing costs and space requirements.
Innovation Solution
A modular assembly method for escalator track systems involving coordinated arrangement and alignment of longitudinal section modules, allowing for horizontal orientation and module-specific assembly, followed by force-fit connections using screws or rivets, minimizing handling effort and enabling precise positioning with minimal assembly aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional escalator assembly processes are used with successive assembly and disassembly steps, then precise positioning and alignment can be achieved, but the manufacturing time and space requirements increase significantly
Solution Approach 1:
The support structure is divided into multiple modular sections that can be assembled independently and then connected. Each module contains standardized connection interfaces that enable precise alignment through coordination marks and guide elements, eliminating the need for time-consuming successive assembly and disassembly operations while maintaining positioning precision.
Solution Approach 2:
Coordination marks and alignment features are pre-marked on the support structure modules during manufacturing. These preliminary markings guide the assembly process, allowing workers to quickly and accurately position modules without requiring time-consuming measurement and adjustment operations during assembly.
2Manufacturing precision
If traditional escalator assembly processes are used with multiple successive assembly steps, then precise positioning can be achieved, but the space requirements for handling and storage increase
Solution Approach 1:
The support structure is segmented into compact modular sections with standardized dimensions and connection interfaces. These modules can be stored in a compact arrangement and assembled in a limited space area, reducing the overall space requirement compared to traditional methods that require large areas for handling and storing complete escalator sections.
Solution Approach 2:
The modular support structure sections are designed to nest or stack together in a compact configuration during storage and handling. This nesting capability significantly reduces the space required for storing multiple modules before assembly, while the standardized connection interfaces ensure precise positioning when the modules are assembled.
3Stability of the object's composition
If the supporting structure is erected along the entire intended length with predefined angular orientation, then the escalator gradient is structurally implemented, but assembly work requires heavy assembly aids like cranes and support arms
Solution Approach 1:
The support structure is divided into modular sections that can be assembled in a horizontal position using simple assembly aids. The angular orientation and gradient are then achieved through coordinated rotation of the assembled modules to the required angle, rather than erecting the entire structure at the predefined angle from the beginning. This segmentation reduces the need for heavy assembly aids like cranes and support arms.
Solution Approach 2:
The assembly process allows for dynamic repositioning of the support structure modules. Modules are first assembled in a convenient horizontal orientation, then the entire assembled structure or individual modules can be rotated to the required angular position. This dynamic approach to assembly eliminates the need for complex fixed-position assembly aids while maintaining structural stability.
4Ease of manufacture
If standardized manufacturing processes are implemented for escalators, then manufacturing costs are reduced, but flexibility and variability in design are limited
Solution Approach 1:
The support structure is divided into standardized modular sections that can be configured in different arrangements to create various escalator designs. The modules feature standardized connection interfaces for cost-effective manufacturing, while the modular nature allows flexible combination to achieve different lengths, angles, and configurations, thus maintaining both standardization benefits and design flexibility.
Solution Approach 2:
The modular support structure modules are designed with universal connection interfaces and standardized features that can be used across different escalator models and configurations. This universality enables standardized manufacturing processes and cost-effective production, while the modular system can be adapted to create various escalator designs by simply changing the arrangement and combination of the same standardized modules.
Data Source
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AI summary
When it comes to track systems, it is important to ensure a good compromise between standardizability and variability, especially with regard to the supporting structure.According to the invention, a modular concept is provided with regard to both the structural design and the assembly method for the entire supporting structure of the track device, wherein by providing and connecting at least two longitudinal section modules of the track device, which is provided in a modular configuration with at least three separate longitudinal section modules consisting of two head modules and at least one intermediate module, a connection/marriage of load-bearing supporting structures of the longitudinal section modules of at least one of the head modules, in particular initially the intended lower head module, takes place in an orientation and/or arrangement corresponding to the orientation/arrangement of the supporting structure of the at least one intermediate module, in particular with the platform section of the (respective) head module in a horizontal orientation.This also ensures good accessibility and ergonomics right up to the final assembly phase. The invention further relates to a corresponding guideway device.