Structural Module Tie Assembly for Misalignment-Tolerant Connections
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Solution Overview
Problem
The construction industry faces challenges in efficiently constructing high-rise buildings in limited spaces with increasing labor costs, requiring improved load support and faster interconnection of structural modules while minimizing the use of structural members.
Innovation Solution
A tie system for structural modules featuring box-section columns and braces joined by welding, with module-to-module ties that include tapered sockets and receivers for accommodating misalignment, and spacers to withstand shear forces, allowing for quick and secure horizontal connections between modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional welding and bolting methods are used to connect modules, then connection strength is achieved, but assembly time and labor costs increase significantly
Solution Approach 1:
The connection system is divided into discrete modular components: plate assemblies with pre-formed sockets, receiver assemblies with threaded rods, and spacer assemblies. These segmented components can be pre-assembled and then quickly connected on-site without extensive welding or bolting, significantly reducing assembly time while maintaining connection strength.
Solution Approach 2:
Critical connection components are pre-assembled and prepared before site installation. The plate assemblies have sockets pre-formed, receiver assemblies have threaded rods pre-installed, and spacers are pre-configured with welding plates. This preliminary preparation eliminates time-consuming on-site fabrication and reduces assembly complexity.
2Device complexity
If fewer structural members are used to support loads, then material costs and complexity are reduced, but load-bearing capacity may be compromised
Solution Approach 1:
Multiple structural functions are merged into integrated assemblies. The plate assemblies combine connection plates, sockets, and mounting features into single components. The receiver assemblies integrate threaded rods with mounting plates. The spacer assemblies combine spacing functions with structural reinforcement through welded plates. This merging reduces the total number of separate structural members while maintaining load-bearing capacity.
Solution Approach 2:
The connection system uses composite construction combining different materials and connection methods. Steel plates are welded to create rigid connections, threaded rods provide tensile strength, and the combination of welded plates and mechanical fasteners creates a composite connection system that achieves high load capacity with fewer components.
3Manufacturing precision
If precise alignment is required for module connections, then connection accuracy is improved, but assembly difficulty and time increase due to tolerance accommodation
Solution Approach 1:
The connection system incorporates adjustable and adaptable features that allow for dynamic alignment during assembly. The tapered sockets provide self-aligning capability, allowing minor misalignments to be accommodated automatically. The threaded rods allow for adjustment of position and orientation. The spacers can be positioned to accommodate varying module dimensions. This dynamic adaptability simplifies assembly while maintaining connection precision.
Solution Approach 2:
Spacer assemblies act as intermediary components between modules, absorbing and compensating for alignment variations. The spacers with welded plates provide a flexible interface that can accommodate tolerance variations in module dimensions and positions, facilitating easier assembly while maintaining overall connection accuracy.
4Strength
If extensive welding and bolting is performed on-site, then connection strength is ensured, but labor costs and construction time increase
Solution Approach 1:
The connection system is segmented into pre-assembled units with welding already performed during manufacturing. Plate assemblies, receiver assemblies, and spacer assemblies are all pre-prepared with welded connections before delivery to site. This eliminates the need for extensive on-site welding, reducing labor costs and construction time while maintaining connection strength through the pre-welded joints.
Solution Approach 2:
All welding and heavy fabrication is performed as preliminary actions during off-site manufacturing of the connection components. The plate assemblies arrive with welded sockets, the receiver assemblies arrive with welded mounting plates, and the spacer assemblies arrive with welded reinforcement plates. This preliminary fabrication transfers complex manufacturing operations from the construction site to the manufacturing facility, greatly simplifying on-site assembly.
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 solution provides efficient vertical load support with fewer materials, enables rapid assembly and adjustment on-site, and allows for secure connections between modules, facilitating the construction of high-rise buildings by accommodating small building tolerances without the need for extensive welding or bolting.
Implementation Method 1
the spacer comprises at least one tapered surface having an edge configured for welding to a plate
Implementation Method 2
the columns and the braces are joined by welding
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
A structural module (1) has a structural frame having structural members forming floor plates (2), wall plates (3), vertical columns (4), braces (7) extending at angles from the columns to the floor plates, and wall studs. The columns and the braces are configured to transfer vertical loads without assistance from the studs. There may be a module-to-module tie (200) affixed to at least one column, and each tie may be affixed to a top surface of a column, to link columns of adjoining modules together in a horizontal plane, and to accommodate misalignment of the modules in the horizontal plane.