Prefabricated Plastic Duct Bank Assembly Using Aligned Extrusion Templates
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Solution Overview
Problem
Existing methods for assembling duct banks are labor-intensive, dangerous, and costly, often requiring on-site assembly, which increases material waste and installation costs, and lack an automated prefabrication process.
Innovation Solution
A method and apparatus for prefabricating duct banks by aligning templates with a pipe extrusion machine, extruding pipes into patterned holes, cutting them to length, and banding the duct bank for transport, using a frame with adjustable positioning systems for precise alignment and automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If duct banks are assembled on-site using manual methods, then flexibility in installation is maintained, but labor intensity and safety risks increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-assembling duct banks in a controlled factory environment using automated equipment before transportation to the installation site. Templates are precisely positioned and pipes are inserted into templates during manufacturing, creating pre-assembled duct bank sections that can be directly installed at the site without manual assembly, thus maintaining installation flexibility while dramatically improving assembly efficiency and worker safety.
2Productivity
If automated prefabrication is implemented, then productivity and precision are improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a multi-functional manufacturing system where a single integrated apparatus performs multiple operations: the frame structure supports templates, the extrusion machine forms pipes, the positioning system aligns components, and the banding mechanism secures the assembly. This multi-functional system achieves automated prefabrication with improved productivity while managing device complexity through functional integration rather than separate specialized machines for each operation.
3Adaptability or versatility
If on-site assembly is performed, then adaptability to site conditions is maintained, but material waste and installation costs increase
Solution Approach 1:
The patent applies preliminary action by performing precise material placement during factory manufacturing. Pipes are cut to exact lengths and inserted into templates with precise positioning, minimizing cutting waste and material errors. The controlled factory environment allows for optimized material usage and reduced errors compared to on-site assembly, thereby reducing material waste while maintaining adaptability through pre-engineered design flexibility.
4Device complexity
If manual alignment and positioning is used, then simplicity of equipment is maintained, but manufacturing precision and assembly time deteriorate
Solution Approach 1:
The patent applies mechanics substitution by replacing manual mechanical alignment operations with an automated positioning system. The frame structure incorporates positioning mechanisms that automatically align templates and pipes with predetermined precision, eliminating the need for manual measurement and adjustment. This substitution of automated positioning for manual alignment achieves high manufacturing precision while managing equipment complexity through integrated design.
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
Reduces labor and material costs, enhances worker safety, and enables efficient, automated assembly of duct banks at the point of pipe extrusion, minimizing waste and installation time.
Implementation Method 1
positioning the frame adjacent an extrusion machine, the extrusion machine having a coaxial extrusion die... extruding a pipe of a first predetermined length into the set of holes
Implementation Method 2
the extrusion machine having a coaxial extrusion die, a cooling section, and a cutter
Data Source
AI summary
A method and apparatus for manufacturing a duct bank comprising the steps of loading a frame with a series of templates, positioning the frame adjacent a pipe extruder, aligning a set of a plurality of holes with a die of the pipe extruder, extruding a pipe of a first length into the set of holes, repeating the steps of aligning and extruding for each set of holes, thereby forming the duct bank, banding the duct bank, and removing the duct bank from the frame.