Rig Mat Replaceable Deck Inserts via C-Channel Frame
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Solution Overview
Problem
Conventional steel frame rig mats have permanently attached wooden deck members, making it difficult and costly to replace damaged inserts, often requiring the entire mat to be replaced rather than repaired.
Innovation Solution
A rig mat design featuring a frame with C-shaped channels and removable flange panels allows for easy insertion and removal of deck inserts, enabling damaged components to be replaced without cutting or welding the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wooden deck members are permanently held by the frame through welding, then the structural strength and stability of the rig mat is improved, but the ease of repair deteriorates because damaged members cannot be easily replaced
Solution Approach 1:
The frame is segmented into multiple C-shaped channels that are distributed along the longitudinal frame members. Each channel independently holds a deck insert, allowing individual inserts to be replaced without affecting the entire frame structure or requiring welding operations.
Solution Approach 2:
The deck inserts are extracted from the permanent welded connection and placed into removable C-shaped channels. This allows the inserts to be easily removed and replaced by simply opening the flange panels, eliminating the need for torch cutting and welding repairs.
2Reliability
If the entire rig mat is replaced instead of repairing damaged wooden members, then the reliability of the rig mat is improved, but the loss of substance and cost increase due to shipping and material waste
Solution Approach 1:
Instead of discarding the entire rig mat when deck inserts are damaged, the design allows for selective discarding and replacement of only the damaged inserts. The C-shaped channels with removable flange panels enable easy removal of damaged inserts while retaining the frame and undamaged components, reducing material waste and shipping costs.
3Ease of repair
If torch cutting and welding is used to replace damaged wooden members, then the ease of repair is improved, but the loss of time and complexity of operation increase due to the extensive repair process
Solution Approach 1:
The repair process is simplified by extracting the deck inserts from permanent welded connections and placing them in removable C-shaped channels. Damaged inserts can be quickly removed by opening flange panels and replaced without any torch cutting or welding operations, dramatically reducing repair time and operational complexity.
Data Source
AI summary
A rig mat frame has at least two longitudinal frame members and at least two lateral frame members defining a deck insert opening therebetween. Each longitudinal frame member has a C-shaped channel facing the deck insert opening and extending along the length of the longitudinal frame member. At least one C-shaped channel has a longitudinally extending flange with a channel opening providing access into the C-shaped channel. A flange panel is removably fastened to the frame and closes the channel opening when the flange panel is fastened to the frame. A plurality of deck inserts are disposed within the frame and extend across the deck insert opening with the ends of each deck insert disposed in the C-shaped channels. And each of the plurality of deck inserts is removable from the C-shaped channels when the deck insert is positioned in alignment with the channel opening and the flange panel is disconnected from the frame.