Prefabricated Component Installation Using Segmented Lifting

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Solution Overview

Problem

Conventional pre-fabricated construction processes are hindered by the limitations of cranes, which require more components to be lifted due to size constraints, leading to longer installation schedules, increased manpower, and safety risks, especially in high-rise buildings where wind and spatial constraints pose challenges.

Innovation Solution

Deploying a system that uses a combination of first and second lifting devices, such as reach stackers and forklifts, equipped with engagement means capable of two degrees of motion, to efficiently transport and install pre-fabricated components, reducing manual labor and coordination needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If pre-fabricated components are made larger to reduce the number of components, then the number of components to assemble is reduced, but the components become heavier and cannot be lifted by conventional cranes

Engineering Contradiction:
Improvenumber of componentsVSAvoidweight of pre-fabricated component
Core Design Contradiction:
Quantity of substanceVSWeight of moving object

Solution Approach 1:

The lifting operation is segmented into two stages: first, a crane lifts the pre-fabricated component to a lower level; second, a reach stacker on that level lifts and positions the component into its final position. This segmentation allows the component to be made larger and heavier while still being installable, as the weight constraint is distributed across two different lifting mechanisms operating at different stages.

Inventive Principle:
Principle #1Segmentation

2Productivity

If conventional cranes are used to lift pre-fabricated components, then lifting capability is maintained, but more components must be lifted resulting in longer installation schedules

Engineering Contradiction:
Improveinstallation speedVSAvoidnumber of components to lift
Core Design Contradiction:
ProductivityVSQuantity of substance

Solution Approach 1:

The lifting operation is segmented into two stages: first, a crane lifts the pre-fabricated component to a lower level; second, a reach stacker on that level lifts and positions the component into its final position. This segmentation allows the component to be made larger and heavier while still being installable, as the weight constraint is distributed across two different lifting mechanisms operating at different stages.

Inventive Principle:
Principle #1Segmentation

3Area of stationary object

If crane boom reaches further areas, then coverage is improved, but the ability to lift heavy components is compromised

Engineering Contradiction:
Improvecrane coverage areaVSAvoidlifting capacity
Core Design Contradiction:
Area of stationary objectVSWeight of moving object

Solution Approach 1:

The lifting operation is segmented into two stages: first, a crane lifts the pre-fabricated component to a lower level; second, a reach stacker on that level lifts and positions the component into its final position. This segmentation allows the component to be made larger and heavier while still being installable, as the weight constraint is distributed across two different lifting mechanisms operating at different stages.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The reach stacker acts as an intermediary device between the ground level and the final installation position. It receives the component from the crane at an intermediate level and completes the lifting operation, thereby extending the effective reach and lifting capability without requiring the crane to maintain high lifting capacity at extreme distances.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Manufacturing precision

If manual labor is used to stabilize and position pre-fabricated components, then installation precision is achieved, but safety risks increase

Engineering Contradiction:
Improveinstallation precisionVSAvoidsafety
Core Design Contradiction:
Manufacturing precisionVSReliability

Solution Approach 1:

The patent replaces manual mechanical stabilization and positioning with an automated reach stacker equipped with engagement means. The reach stacker mechanically grasps the pre-fabricated component and uses its powered positioning system to align and install the component, eliminating the need for workers to manually stabilize heavy components and thereby reducing safety risks while maintaining installation precision.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11193287B2Construction system and method
Publication Date: 2021.12.07 SH TECH PTE LTD
  • US11193287B2 patent drawing
  • US11193287B2 patent drawing
  • US11193287B2 patent drawing

AI summary

A system for assembling a plurality of pre-fabricated components to form a structure comprising: a first lifting device for transporting at least one pre-fabricated component from a source to a designated site; a second lifting device for engaging the at least one pre-fabricated component at the designated site; wherein the second lifting device comprises an engagement means to engage a portion of the at least one pre-fabricated component for installation at the designated site, and wherein the engagement means is capable of moving the engaged pre-fabricated component in at least two degrees of motion, is disclosed. In some embodiments, the engagement means comprises a plurality of locks.