Modular Support Frame Flange Connectors Assembly
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Solution Overview
Problem
Existing modular support frames for housing and platforms require significant labor and equipment for assembly, as they often necessitate the use of cranes and complex fastening systems, such as nut and bolt connections and T-braces, to achieve stability.
Innovation Solution
A modular support frame design utilizing flange-type connectors and complementary connectors, allowing for efficient assembly of trusses, vertical posts, and purlins, which can be assembled by two workers in a matter of hours, using a configuration where trusses are connected by flange-type connectors and purlins are secured with complementary connectors, reducing the need for extensive labor and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional modular foundation structures with tubular struts and nut-bolt fasteners are used, then structural stability is achieved, but assembly complexity and labor requirements increase significantly
Solution Approach 1:
The foundation structure is divided into modular units (trusses, posts, purlins) that can be independently manufactured and assembled. Each module contains integrated connectors, allowing simple assembly through connection rather than complex fastening operations.
Solution Approach 2:
The connector functions are merged directly into the truss and post structures. Flange-type connectors are welded to trusses and posts, eliminating the need for separate fasteners. The complementary connector design integrates the joining mechanism into the components themselves, reducing assembly complexity while maintaining stability.
2Stability of the object's composition
If cranes and complex fastening systems are used for assembly, then structural stability is ensured, but assembly time and equipment requirements increase
Solution Approach 1:
The structure is segmented into manageable modules that can be handled by two workers without crane assistance. The modular design with integrated connectors enables quick assembly operations that reduce overall assembly time while maintaining structural integrity.
Solution Approach 2:
The flange-type connectors and complementary connectors are designed to be self-aligning and self-securing through wedge insertion. The wedge automatically secures the joint when inserted through the opening, eliminating the need for complex fastening procedures and reducing assembly time.
3Strength
If traditional support frames are designed for structural stability, then load-bearing capacity is achieved, but weight increases
Solution Approach 1:
The support frame uses aluminum material that provides high strength-to-weight ratio. The trusses, posts, and purlins are constructed from aluminum sections that maintain load-bearing capacity while significantly reducing overall frame weight compared to traditional steel structures.
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 support frame can be efficiently assembled by two workers in a shorter time, reducing labor costs and assembly time, while providing a stable foundation for housing and platforms, with the option to use aluminum for weight reduction.
Implementation Method 1
The complementary connector comprises openings in the upper and lower sections of the complementary connector that allow a wedge to be received and extended through one of the openings in the flange, thereby securing the joint.
Implementation Method 2
The wedge is received and extended through one of the openings in the flange, thereby securing the joint.
Implementation Method 3
The flange is connected as by welding to one component to be joined.
Data Source
AI summary
A modular support frame comprises trusses, purlins transverse to the trusses, and vertical posts supporting the various trusses. A supply of wedges permits flange-type connectors to be joined to complementary connectors throughout the foundation. The trusses are arranged end-to-end in parallel rows, each row comprising at least one pair of trusses or more depending on the desired size of the foundation. Vertical posts are positioned between the ends of each of the trusses within a row and at opposing ends of the row, and each post comprises a pair of flange-type connectors at predetermined heights. Each of the trusses is terminated at either end with a pair of complementary connectors such that adjacent in-line trusses can be mounted to the post between them and the outer pair of trusses can be mounted to the posts terminated the row. Purlins extend perpendicularly between the trusses in adjacent rows to reinforce the frame. To that end, the trusses comprise flange-type connectors and the purlins are terminated at either end with complementary connectors.