Road Cap Frame with U-Shaped Compensating Elements
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Solution Overview
Problem
Road cap and manhole cover installations face issues with rattling noises due to manufacturing tolerances, which are costly to resolve with precise manufacturing, and lead to wear when the frame is made of plastic.
Innovation Solution
The use of independent, evenly distributed U-shaped compensating elements between the frame and cover, made of soft plastic, which create a press fit and act as centering, tolerance compensation, and anti-rattle elements, allowing for drainage and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If manufacturing tolerances are reduced to eliminate play between cover and frame, then rattling noises are eliminated, but production costs increase enormously
Solution Approach 1:
The patent introduces compensating elements as intermediary components between the cover and frame. These elements absorb the manufacturing tolerances and eliminate play without requiring precise manufacturing of the main components. The compensating elements act as a mediator that takes up the dimensional variations, thereby eliminating rattling noises while keeping production costs low.
Solution Approach 2:
The patent changes the parameter of dimensional compensation from the main components (cover and frame) to separate compensating elements. By transferring the tolerance absorption function to these additional elements with specific dimensional parameters, the system achieves tight fit without requiring expensive precision manufacturing of the primary components.
2Manufacturing precision
If manufacturing tolerances are reduced to eliminate play between cover and frame, then fit precision is improved, but production costs increase enormously
Solution Approach 1:
The compensating elements serve as intermediaries that absorb manufacturing tolerances. Instead of requiring the cover and frame to be manufactured with tight tolerances, these intermediary elements take up the dimensional variations and provide the necessary fit precision through their own controlled dimensions and elastic properties.
Solution Approach 2:
The patent segments the fit precision function into two parts: the main components (cover and frame) which can be manufactured with standard tolerances, and the compensating elements which are specifically designed to provide the precise fit. This segmentation allows standard manufacturing processes to be used for the main components while achieving high fit precision through the specialized compensating elements.
3Ease of manufacture
If the frame is made of plastic to reduce weight and cost, then manufacturing cost is reduced, but wear occurs due to tolerance-related relative movement
Solution Approach 1:
The compensating elements act as intermediaries between the plastic frame and the cover, preventing direct contact and relative movement between these components. By absorbing the tolerance variations, these elements eliminate the wear mechanism that would otherwise occur in the plastic frame, thereby maintaining reliability while keeping manufacturing costs low.
Solution Approach 2:
The compensating elements provide beforehand cushioning by absorbing dimensional variations before they can cause wear in the plastic frame. These elements are designed to take up the tolerance-related movements in advance, protecting the plastic frame from wear through their own deformable or replaceable nature.
4Manufacturing precision
If compensating elements are added to eliminate play, then fit precision is improved, but device complexity increases
Solution Approach 1:
The compensating elements are designed as simple, inexpensive components that can be easily manufactured and replaced. Their simplicity and low cost offset the increase in component count, as they are far cheaper than the alternative of precision-manufactured cover and frame assemblies. The ease of replacement further reduces the practical impact of the additional components.
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
The solution effectively eliminates rattling noises during transport and installation, maintains a secure fit, and allows for easy replacement of worn components, reducing manufacturing costs and wear on plastic frames.
Implementation Method 1
U-förmige Kompensations Elemente, die den Einbaubereich von der Einbauseite her umfangen, wobei die Kompensations Elemente zwischen Rahmen und Deckel wirken, sodass bei Einbau der Deckel in den Rahmen der Spielraum zwischen Rahmen und Deckel zumindest verringert oder ein Sitz, bevorzugt ein Presssitz, erzeugt wird
Data Source
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AI summary
A device for preferably flush installation in the road surface, for example road caps, drainage shafts, inspection openings or the like, comprising a frame defining an opening and a cover that can be positioned with play in the frame, wherein specific individual compensating elements act between the frame and the cover in such a way that when the cover is inserted the play between the frame and the cover is at least reduced or a fit, preferably an interference fit, is created, wherein the compensating elements are components independent of the cover and frame.