Reconfigurable Stud Rail Assembly for Faster Concrete Reinforcement
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Solution Overview
Problem
Conventional stud rail systems for reinforcing concrete structures are difficult to assemble properly and can compromise structural integrity, and the assembly process is time-consuming and costly.
Innovation Solution
A stud rail system comprising rotatably connected rail and cross portions with support projections and assemblies, allowing reconfiguration between collapsed and expanded configurations, which are arranged during concrete pouring to ensure proper placement and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional stud rail systems are used with flat bar stock and pins, then the structural reinforcement function is achieved, but the assembly process becomes time-consuming and difficult to assemble properly
Solution Approach 1:
The stud rail system is divided into multiple modular components including rail portions, cross portions, support assemblies, and connection elements. Each component can be manufactured separately and assembled through simple connection mechanisms, eliminating the need for complex welding operations and reducing assembly time while maintaining structural integrity.
Solution Approach 2:
Connection elements such as pins, bolts, or interlocking features are pre-installed or pre-configured on components during manufacturing. This preliminary action allows for rapid assembly on-site without requiring complex field operations, thereby reducing assembly time and minimizing the risk of improper installation.
2Reliability
If conventional stud rail assembly methods are used, then structural reinforcement is provided, but improper assembly can compromise structural integrity
Solution Approach 1:
Connection elements are designed with asymmetric geometries that allow insertion in only one correct orientation. This asymmetric design provides built-in error prevention, ensuring that components can only be assembled properly and cannot be incorrectly installed, thereby maintaining structural integrity while remaining easy to operate.
Solution Approach 2:
The system incorporates self-aligning features, self-centering mechanisms, or self-locking connection elements that automatically guide components into the correct position during assembly. This self-service capability eliminates the need for complex alignment procedures or specialized expertise, making proper assembly straightforward while ensuring reliable structural connection.
3Adaptability or versatility
If multiple configurations of stud rails are engineered for different locations, then structural requirements are met, but the complexity of the system increases
Solution Approach 1:
The stud rail system employs universal components and standardized connection interfaces that can be used across multiple locations and configurations. By designing modular elements that can be arranged in various patterns and combined in different ways, the system achieves adaptability to different structural requirements without increasing overall complexity, as the same basic components serve multiple functions.
Data Source
AI summary
A stud rail system comprising at least one stud rail assembly. The at least one stud rail assembly comprises a plurality of rail portions, a plurality of cross portions, where a plurality of sets of support openings are formed in each of the plurality of the cross portions, a plurality of pin projections, where each rail portion supports at least one pin projection, a plurality of support assemblies, and a plurality of support projections, where each support projection is supported by one of the plurality of support assemblies. Each of the support projections extends through one of the support openings in each set of support openings such that the rail portions are rotatably connected to cross portions at a plurality of axis points to allow the stud rail assembly to be reconfigured between a collapsed configuration and an expanded configuration.