Modular Trackway Device with Form-Fit Contours for Accurate Assembly
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Solution Overview
Problem
The existing methods for manufacturing escalators and similar passenger transport systems face challenges in achieving high accuracy and efficiency due to complex assembly processes, frequent intermediate steps, and high manufacturing costs, which result in increased space requirements and reduced design flexibility.
Innovation Solution
A modular track device design featuring three longitudinal section modules with form-fitting contours for precise coupling and welding, allowing for high accuracy and variability in the assembly process, particularly using laser cutting and welding techniques to create a standardized and efficient support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional assembly methods with multiple intermediate steps are used, then manufacturing flexibility is maintained, but manufacturing time and complexity increase significantly
Solution Approach 1:
The support structure is divided into multiple longitudinal section modules that can be manufactured separately and then assembled. Each module contains standardized connecting interfaces that enable modular construction, reducing overall assembly time and complexity while maintaining manufacturing flexibility.
Solution Approach 2:
The connecting interfaces are pre-configured with form-fitting contours during module manufacturing. This preliminary preparation eliminates the need for complex on-site adjustments and alignment operations, significantly reducing assembly time and intermediate steps.
2Manufacturing precision
If conventional joining methods are used, then design standardization is achieved, but positioning accuracy decreases
Solution Approach 1:
The connecting interfaces feature localized form-fitting contours with specific geometric configurations that provide precise positioning in critical areas. These localized precision features are integrated into the modular design, achieving high positioning accuracy without requiring expensive precision manufacturing across the entire structure.
3Manufacturing precision
If modular construction with form-fitting contours is implemented, then positioning accuracy is maximized, but manufacturing complexity increases
Solution Approach 1:
The form-fitting contours serve multiple functions simultaneously: they provide precise positioning, ensure proper orientation of adjacent modules, and create stable mechanical connection. This multi-functionality integrates several manufacturing requirements into a single design feature, reducing overall manufacturing complexity despite the precision requirements.
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
This approach enables the creation of escalators with high manufacturing accuracy and standardization, reducing assembly complexity and costs while maintaining design flexibility, thereby improving the overall efficiency and safety of the process.
Implementation Method 1
produced in particular by means of laser cutting
Implementation Method 2
subsequent material-to-material connection of the coupled longitudinal sections, in particular by welding
Data Source
Figure 1~3
Figure 4A~4C
Figure 5A~5C
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 modular assembly of at least one longitudinal section module of a modularly assembleable track system, the track system is provided in a modular configuration with at least three separately/independently produced longitudinal section modules, comprising two head modules and at least one intermediate module, prior to the connection of at least two longitudinal section modules of the track system. Geometrically corresponding form-fit contours are incorporated into at least two adjacent longitudinal sections of the support structure, particularly by means of laser cutting. These contours enable the positioning of the adjacent longitudinal sections for subsequent work steps (e.g., welding). This also ensures high accuracy.The invention further relates to a corresponding assembly method.