Integral Precast Concrete Weldment for Lower-Cost Reliable Joints
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Solution Overview
Problem
Existing precast concrete connectors are costly due to high material and labor expenses, and prone to human error, as they require multiple materials and manual welding, which affects the quality and efficiency of connections under various loads.
Innovation Solution
A machine-made weldment with a top plate and side plate integrally formed at 90°, featuring angled legs with saw teeth for enhanced shear and tensile capacity, and a threaded aperture for secure embedding, manufactured with minimal waste to reduce costs and ensure quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials and manual welding are used to create connectors, then the connection strength and reliability are improved, but the material cost and labor cost increase significantly
Solution Approach 1:
The patent combines multiple separate components (flat steel plate and rebar) into a single integrally formed weldment. This unified structure eliminates the need for separate materials and manual assembly, reducing both material cost and labor cost while maintaining connection reliability through the integrated design that provides both welding surface and reinforcement functions in one piece.
Solution Approach 2:
The integrally formed weldment serves multiple functions simultaneously: it provides a welding surface for connection, acts as reinforcement within the concrete, and resists various loads (tension, shear, bending). This multi-functionality eliminates the need for separate components, reducing manufacturing complexity and cost while ensuring reliable structural connection.
2Strength
If multiple materials and manual welding are used, then the connection capacity under various loads is improved, but human error increases and quality control becomes difficult
Solution Approach 1:
The integrally formed weldment is manufactured as a single piece with built-in features that automatically ensure proper geometry and reinforcement placement. The integral structure self-ensures correct alignment and positioning, eliminating human error in assembly and making quality control easier through consistent factory production rather than field fabrication.
Solution Approach 2:
The patent changes the manufacturing approach from manual fabrication with multiple materials to automated stamping of a single integral structure. This parameter change in the manufacturing process (from manual to automated, from multi-material to single-piece) improves manufacturing precision and reduces human error while maintaining the connection capacity needed to withstand various loads.
3Strength
If traditional connectors with multiple components are used, then the connection strength is sufficient, but the material waste and manufacturing complexity increase
Solution Approach 1:
By merging the flat plate and rebar into a single integrally formed weldment, the patent eliminates the material waste associated with joining separate components. The continuous integral structure uses material more efficiently, and the automated stamping process minimizes manufacturing waste compared to traditional fabrication methods that require cutting, welding, and assembly of multiple pieces.
4Force
If traditional multi-component connectors are used, then the connection capacity is adequate, but the labor cost and installation time increase
Solution Approach 1:
The integrally formed weldment requires no assembly or field fabrication - it is inserted as a complete unit and welded directly. This self-contained design eliminates labor-intensive steps of assembling multiple components, reducing both labor cost and installation time while maintaining the connection capacity to resist lateral wind loads, earthquake loads, and other forces.
Solution Approach 2:
The patent replaces the mechanical assembly process (manual welding of multiple components) with a single-step field welding operation on an integrally formed piece. This substitution of the manufacturing system (from multi-step field fabrication to single-step field welding) improves productivity and reduces labor costs while preserving the structural connection capacity.
Data Source
AI summary
A weldment that is embedded in a precast concrete building member that is used to join the concrete building member to other concrete building members. The weldment has a top plate, side plate, and outstanding top and bottom legs. The surface of the top plate and side plate are not embedded in the precast concrete building member. The legs are integrally formed with the top plate and side plate. The top plate and side plate present weldable surfaces to join by welding the precast concrete building member to another building member.