Rosette Connection via Edge Deformation for Scaffold Tubes
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Solution Overview
Problem
Welding rosettes to metal pipes for scaffolding requires manual labor and causes structural changes, and galvanized pipes often need additional treatment after welding, making the process costly and inefficient.
Innovation Solution
A method where the edge area of the rosette's through-hole is bent out to exceed the pipe's dimensions, then pressed back to create a force and form fit by deforming both the rosette and pipe, allowing for a secure connection without welding, enabling surface treatment before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect rosettes to metal pipes, then the connection strength is improved, but manual labor requirements increase and structural changes occur in the pipe
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a cold-forming mechanical pressing system. The edge area of the rosette is pressed against the pipe using a pressing device, creating a mechanical interlock through plastic deformation of the edge area into the pipe surface, thereby eliminating the need for welding operations and associated manual labor.
Solution Approach 2:
The patent changes the physical state and geometry parameters of the rosette's edge area through plastic deformation. The edge area is locally deformed from its original flat state into a pressed-in configuration on the pipe surface, changing its shape and position parameters to create an interference fit that provides strong mechanical connection without thermal processes.
2Strength
If welding is used to connect rosettes to galvanized pipes, then the connection is achieved, but additional galvanizing treatment is required after welding
Solution Approach 1:
The patent performs the connection operation before any surface treatment is needed. By using cold-forming pressing instead of welding, the connection is established in a state that does not damage surface coatings. This eliminates the need for post-welding galvanizing or other protective coating applications, saving time and additional processing steps.
3Reliability
If the edge area of the through-hole is pressed back into the plane of the rosette, then a force fit and form fit are achieved between the rosette and pipe, but deformation work is required
Solution Approach 1:
The patent applies localized deformation only to the edge area of the rosette rather than the entire component. The pressing operation is concentrated on the specific region that interfaces with the pipe, creating local plastic deformation that generates the interference fit. This localized approach minimizes the total deformation work required compared to deforming the entire rosette or pipe.
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
This method eliminates the need for manual welding, reduces costs, and allows for surface treatment of both components before connection, ensuring a strong and even load distribution without requiring post-treatment galvanizing.
Implementation Method 1
the edge area of the through-hole is bent out of the plane of the rosette... after positioning the rosette on the pipe the edge area surrounding the through-hole is pressed back into the plane of the rosette... causing both deformations of the rosette and deformations of the pipe
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The method involves bending an edge region (5) of a through-hole (3) out of a plane of a collar so that an internal spacing (C) of opposite edges of the through-hole is greater than an outer dimension (D) of a pipe (1). The edge region is pushed back into the plane of the collar according to positioning of the collar on the pipe. The internal spacing of the opposite edges of the through-hole is reduced to a certain level that is smaller than the outer dimension of the pipe, where the internal spacing is determined by free ends of cantilever arms. An independent claim is also included for a scaffold support comprising a collar.