Modular Assembly Mold for Prefabricated Stairs
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Solution Overview
Problem
Current prefabricated concrete stairs designs require multiple molds for different dimensions, leading to increased mold costs and inefficient construction due to conventional design methods that result in excessive dimensions and limited reuse of molds.
Innovation Solution
A modular assembly mold system with adjustable modules, including rotating sections, sliding slots, and precise locating holes, allows for the assembly of stairs of various specifications using a single set of molds, reducing manufacturing costs and construction duration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional design methods are used to design concrete structures and then split them, then the design process is simple, but the prefabricated stairs have excessive dimensions requiring multiple molds
Solution Approach 1:
The mold is divided into multiple independent modules including base module, platform module, stair module, and connection module. Each module can be independently adjusted and reconfigured to produce different stair specifications, enabling a single mold system to replace multiple fixed-dimension molds.
Solution Approach 2:
The mold incorporates adjustable and movable components such as the connection module with sliding slots and rotating mechanisms. These dynamic elements allow the mold geometry to be changed between uses, transforming a static single-purpose mold into a dynamic multi-purpose system.
2Adaptability or versatility
If multiple molds are prepared for different stair dimensions, then all stair specifications can be produced, but the mold cost and running cost increase
Solution Approach 1:
The mold system is designed as a universal platform where the base module, platform module, and connection module can be combined in various configurations to produce multiple stair specifications. This multi-functional design allows one mold system to perform the work of several specialized molds.
Solution Approach 2:
The mold uses adjustable parameters such as the number of standard modules, the position of sliding slots, and rotation angles to change the output dimensions. By varying these parameters, the same physical mold can produce different stair sizes without requiring additional molds.
3Productivity
If conventional molds are used, then the mold structure is simple, but the construction duration is extended due to inefficient assembly
Solution Approach 1:
The mold is segmented into standardized modules that can be quickly assembled and disassembled. The connection module includes pre-designed interfaces with locating holes and sliding slots that enable rapid module assembly, significantly improving assembly efficiency compared to conventional monolithic molds.
Solution Approach 2:
The mold modules are pre-designed with standardized connection interfaces, locating features, and alignment mechanisms. This preliminary preparation of modular components with built-in assembly guides allows for rapid on-site assembly without requiring complex adjustment procedures during construction.
Data Source
AI summary
A prefabricated stair modular assembly mold comprises a base, a step standard module, an upside module of a lower platform, an underside rotating module of a lower platform, an upside module of an upper platform, an underside rotating module of an upper platform, an underside common module, and an underside adjustment modules. Prefabricated stair molds of different dimensions are formed by means of locating holes provided in the assembling modules, and are then fixed by means of sliding holes at two ends. Further disclosed is a mounting method for said assembly mold. Said assembly mold has high positioning accuracy, and small accumulated error, improving the mounting efficiency of the prefabricated staircase mold.