Segmented Sheet Metal Spacer for Guide Rail Mounting
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Solution Overview
Problem
Existing intermediate pieces for guide devices, such as those described in AT 409 275 B, are difficult to manufacture as single shaping operations due to their tubular sheet metal design, which complicates production and assembly.
Innovation Solution
The intermediate piece is composed of two identical half-shells made from sheet metal, each produced in a single shaping operation by bending, which can be easily assembled into a tubular form using screws for attachment to uprights and guide rails, allowing for straightforward connection and attachment of guide rails or retaining brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tubular intermediate piece is made from a single sheet metal blank, then the damping effect is maintained, but the manufacturing complexity increases and cannot be done in a single shaping operation
Solution Approach 1:
The tubular intermediate piece is divided into two separate C-shaped half-shells instead of being made from a single continuous sheet metal blank. Each half-shell can be manufactured independently in a single shaping operation, and then assembled together to form the complete tubular structure. This segmentation resolves the contradiction by enabling simpler manufacturing while maintaining the tubular geometry required for damping functionality.
2Reliability
If the intermediate piece is made as a one-piece tubular structure, then the damping effect is achieved, but the production time and manufacturing difficulty increase
Solution Approach 1:
By dividing the tubular intermediate piece into two separate C-shaped half-shells, each component can be manufactured independently and simultaneously in single shaping operations. This parallel manufacturing capability significantly reduces production time compared to creating a complete tubular structure in one complex operation, while the assembled tubular structure maintains the necessary damping effect.
3Ease of manufacture
If the intermediate piece is made from two half-shells, then the ease of manufacture improves, but the device complexity increases due to assembly requirements
Solution Approach 1:
The two C-shaped half-shells are designed to be assembled together to form a complete tubular intermediate piece. This merging of two simple components creates the functional tubular structure needed for damping, while the assembly process is simplified by the complementary C-shape design that naturally aligns and connects. The benefit of simplified manufacturing of individual components outweighs the minor increase in assembly steps.
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 design simplifies production and maintains the damping effectiveness of the original intermediate piece, ensuring a uniformly rising force deformation curve and high load-bearing capacity, preventing deformation under significant loads and maintaining the guide rail's position.
Implementation Method 1
each half-shell 3 can be produced in a single shaping operation from a sheet metal blank by bending
Implementation Method 2
the intermediate piece serves to form a damping element which is arranged between the uprights of the guide device and the guide rail
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
An intermediate piece (1) for guide devices, consisting of posts (9) anchored in the ground or attached to a structure and guide rails (13) attached to the posts (9) via intermediate pieces (1), comprises two identical half-shells (3). Each half-shell (3) is formed from sheet metal (steel sheet) and has a circularly curved web (7) and adjoining this web two parallel, flat legs (5). These flat legs (5) abut each other when the half-shells (3) are assembled to form the essentially tubular intermediate piece (1). The intermediate piece (1) is attached to the post (9) via the overlapping legs (5) of the half-shells (3) using connecting screws. The guide rail (13) can be attached to the overlapping legs (5) of the half-shells (3) furthest from the post (9), optionally via a retaining bracket (11), optionally using connecting screws.The advantage here is that the screws with which the half-shells (3) are connected to form the tubular intermediate piece (1) can be used simultaneously to fasten the intermediate piece (1) to uprights (9) and to fasten the guide rail (13) or retaining brackets (11) for it to the intermediate piece (1).