Monolithic Connector Plate for Structural Truss Welding

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Solution Overview

Problem

Existing structural truss connection methods face challenges due to heat affected zones from welding, which reduce the allowable stress and require larger tubes or plates, increasing weight and cost, while also limiting the space for fasteners and reducing load-bearing capacity.

Innovation Solution

The use of monolithic connector plate members with a corner beam section, main plate section, and lip design that minimizes welding and heat affected zones, allowing for smaller tubes and improved fastener placement, and the introduction of a junction block connector with double-sided connector plate members for enhanced stability and ease of assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to connect connector plates to structural truss tubes, then the connection is formed, but heat affected zones are created that reduce allowable stress and require larger tubes or plates, increasing weight and cost

Engineering Contradiction:

Improveconnection strengthVSAvoidweight of structural truss

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The connector plate is divided into multiple sections: a corner beam section that interfaces with the tube, a main plate section for fastener attachment, and a lip section. This segmentation allows each part to be optimized for its specific function while minimizing the overall welding required and reducing heat affected zone impact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector plate acts as an intermediary element between the structural truss tube and the fastening system. It distributes the load from fasteners across a wider area and provides a stable interface that reduces stress concentration at the welding zones, allowing smaller tubes to be used.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If larger tubes and plates are used to compensate for heat affected zones, then the allowable stress is maintained, but the weight increases and the space for fasteners is reduced

Engineering Contradiction:

Improveallowable stressVSAvoidspace for fasteners

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The connector plate has different sections with different properties: the corner beam section provides structural interface, the main plate section provides fastener mounting area, and the lip section provides additional support. This local differentiation allows the fastener area to be adequately sized without requiring larger overall tube dimensions.

Inventive Principle:

Principle #3Local quality

3Strength

If fasteners are located as close as possible to the corners of the structural truss to increase strength, then the load bearing capacity is improved, but the heat affected zones reduce the allowable stress in the end plates

Engineering Contradiction:

Improveload bearing capacityVSAvoidstress in end plates

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The connector plate extends in multiple dimensions from the tube interface, creating a distributed load path that moves forces away from the corner regions and through the main plate section where there is more material capacity to handle the stress.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution reduces assembly time, minimizes heat affected zones, and maintains structural integrity by distributing loads effectively across a wider area, enhancing the load-bearing capacity and reducing mechanical stress on end plates.

Implementation Method 1

at least one of the opposing ends of the structural truss including at least one connector plate member welded to the framework between two corresponding longitudinal tubes

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

maintains structural integrity by distributing loads effectively across a wider area, enhancing the load-bearing capacity and reducing mechanical stress on end plates

Methodology Applied

Scientific EffectStress distribution:

Implementation Method 3

the corner beam section including two opposite ends, each having a corresponding first cutout configured and disposed to fit around an end of the corresponding longitudinal tubes

Methodology Applied

Scientific EffectMechanical fit:

Implementation Method 4

a lip projecting at right angle from the main plate section on the rear side of the connector plate member, the lip extending substantially parallel to the corner beam section

Methodology Applied

Scientific EffectGeometric constraint: Geometry

Data Source

PatentUS8978338B2Structural trusses with monolithic connector plate members

Publication Date: 2015.03.17 LES ENCEINTES ACOUSTIQUES UNISSON

AI summary

The structural truss includes a connector plate member welded to the framework between two corresponding longitudinal tubes. The connector plate member is made of a monolithic piece. It includes a corner beam section protruding from the rear side of the connector plate member and a main plate section extending perpendicularly inwards on a side of the corner beam section. The main plate section and the corner beam section define together a planar outer abutment plate surface. The connector plate member also includes a lip projecting at right angle from the main plate section on the rear side of the connector plate member. The lip extends substantially parallel to the corner beam section.