Modular Rooftop Support Clamp with Tab-Defined Beam Retention
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Solution Overview
Problem
Current rooftop support structures for equipment like air conditioning units require lengthy assembly times, are not easily customizable, and often necessitate permanent fasteners, limiting adaptability and increasing installation time.
Innovation Solution
A modular rooftop support system featuring adjustable clamps and crossbeam assemblies with U-shaped connectors and telescoping rods, allowing for quick assembly and customization, with clamps that can securely hold beams using threaded fasteners and tabs to define a reduced-clearance entrance region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rooftop support structures use permanent fasteners and fixed designs, then structural stability is improved, but installation time increases and adaptability decreases
Solution Approach 1:
The support structure is divided into modular components (clamps, posts, crossbeams, equipment supports) that can be independently manufactured and assembled. The clamp assembly separates the beam-clamping function from the post-mounting function, allowing pre-assembly of clamp-beam units that can be quickly installed on rooftops without extensive permanent fastening operations.
Solution Approach 2:
The clamp incorporates adjustable elements including telescoping rods with locking mechanisms and rotatable components that allow the structure to adapt to different equipment sizes and configurations. The threaded rod with lock nut provides adjustable length, and the rotatable clamp body enables orientation adjustment, maintaining structural stability while accommodating variations during installation.
2Ease of manufacture
If traditional support structures use fixed non-modular designs, then manufacturing simplicity is improved, but customization capability and adaptability deteriorate
Solution Approach 1:
The clamp assembly is designed as a universal component that can accommodate various beam sizes and equipment types through its adjustable features. The same basic clamp design with telescoping rods and locking mechanisms can be used across different support structure configurations, reducing the number of unique parts needed while maintaining customization capability.
Solution Approach 2:
The structure utilizes adjustable parameters including rod length (via telescoping and threading), clamp orientation (via rotation), and positioning (via movable clamp bodies on posts) to adapt to different equipment requirements. These parameter adjustments allow a single modular design to serve multiple customization needs without requiring different manufactured parts.
3Strength
If traditional structures require extensive permanent fastening, then structural robustness is improved, but installation complexity and time increase
Solution Approach 1:
The clamp and beam are pre-assembled as integrated units before installation, with the clamp already positioned and secured to the beam. This preliminary assembly reduces on-site installation steps, as the pre-assembled units only require mounting to the post and securing with the threaded rod and lock nut, rather than requiring complex fastening operations during installation.
Solution Approach 2:
The threaded rod with lock nut serves as an intermediary fastening mechanism that simplifies the connection between modular components. Instead of requiring multiple permanent fasteners welded or bolted to structural elements, the threaded rod provides a simple, reversible, and robust connection that maintains structural integrity while reducing installation complexity.
4Adaptability or versatility
If modular components with multiple adjustment features are used, then adaptability is improved, but component complexity increases
Solution Approach 1:
Multiple adjustment functions are merged into integrated components rather than separate mechanisms. The telescoping rod combines length adjustment with structural support, the lock nut provides both locking and positioning functions, and the rotatable clamp body integrates orientation adjustment with the clamping mechanism. This merging reduces the number of separate parts while maintaining adjustability.
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 modular system reduces installation time, enhances ease of installation, and allows for customizable and adjustable support structures to accommodate various equipment heights and configurations, improving adaptability and robustness.
Implementation Method 1
a threaded fastener that extends through a threaded opening in a first wall of the clamp into the interior volume to clamp the beam into a third wall of the clamp
Implementation Method 2
a threaded fastener that extends through a threaded opening in a first wall of the clamp into the interior volume to clamp the beam into a third wall of the clamp
Implementation Method 3
a tab extending from the third wall at least partly toward the first wall to further define the interior volume and retain the support beam within the interior volume
Data Source
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AI summary
A rooftop support system (100) can include a base (116) to support the rooftop support structure on a rooftop, and a post (120) secured to and extending upwardly from the base. The rooftop support system can further include a clamp (108) secured to the post to be supported by the post relative to the base. The clamp can include a first wall, a second wall extending from the first wall, and a third wall extending from the second wall, so that the first, second, and third walls partly define an interior volume of the clamp. A tab (164) can extend from the third wall at least partly toward the first wall to further define the interior volume.