Spun Pile End Plate Interlocking Joint Design
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Solution Overview
Problem
Existing end plate systems for joining concrete piles face issues such as pin rotation under tension, increased installation time, and higher material costs due to complex joint configurations and the need for multiple pins, which reduce the strength and practicality of the connection.
Innovation Solution
The end plate system features interlocking profiles with segmental protrusions and recesses that allow for two types of joints through rotation and pin insertion, reducing the number of pins required and utilizing a single-stage Hot Forging Closed Mold process for mass manufacturing, resulting in a stronger, cost-effective, and faster installation method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional end plate systems use multiple pins to interlock the joint, then the connection strength is improved, but the installation time increases and the complexity of the joint configuration increases
Solution Approach 1:
The interlocking joint is segmented into multiple passageways arranged radially, allowing pins to be distributed across different locations. This segmentation enables parallel insertion of multiple pins simultaneously, reducing installation time while maintaining connection strength through distributed load paths.
Solution Approach 2:
The end plates are pre-configured with multiple passageways during manufacturing, so that during installation, pins can be directly inserted into predetermined locations without requiring complex alignment procedures. This preliminary preparation significantly reduces installation time while ensuring proper pin placement for optimal connection strength.
2Strength
If traditional end plate systems use complex joint configurations with multiple pins, then the connection strength is improved, but the material costs increase
Solution Approach 1:
Instead of using enough pins to completely fill all possible passageways, the system uses a optimized subset of pins strategically placed in critical passageways. This partial action approach provides sufficient connection strength for the intended load conditions while minimizing the number of pins required, thereby reducing material costs.
Solution Approach 2:
Different regions of the end plate joint have different pin density requirements. The radial passageway configuration allows for local optimization where pins are concentrated in areas experiencing higher stress concentrations, while fewer or no pins are used in lower-stress regions, achieving cost-effective material usage without compromising overall connection strength.
3Reliability
If tapered pins are advanced into passageways sequentially in stages, then the interlocking is achieved, but the installation time increases
Solution Approach 1:
Multiple passageways are pre-formed during end plate manufacturing with precise dimensions and orientations. This preliminary action eliminates the need for sequential trial-and-error pin insertion, allowing workers to simultaneously insert multiple pins into pre-positioned passageways, dramatically increasing installation speed while maintaining interlocking reliability.
Solution Approach 2:
The pin insertion process is segmented into independent parallel operations across multiple radial passageways. Instead of sequentially advancing pins through a single passageway in stages, workers can simultaneously insert pins into multiple segregated passageways, transforming a serial process into a parallel one that maintains reliability while boosting productivity.
Data Source
AI summary
The present invention discloses an end plate system for joining spun piles together comprises a top end plate (100) mounted at a bottom end of a first spun pile: and a bottom end plate (200) mounted at a top end of a second spun pile; wherein the end plates (100, 200) respectively have an interlocking surface that is formed with a plurality of segmental protrusions (110, 210) and segmental recesses (120, 220) arranged in an alternate configuration; characterized in that each segmental protrusion (110, 210) has a first radial interlocking profile (111, 211) and a second radial interlocking profile (112, 212) that extend towards the central portion of the end plates (100, 200); wherein the top end plate (100) and the bottom end plate (200) are mated by registering the segmental protrusion (110, 210) of one end plate to the segmental recess (120, 220) of another end plate and through a rotating movement about the central axis of the mated end plates (100, 200), a first interlocking joint (300) is formed by two adjacent first radial interlocking profiles (111, 211) in full surface contact, and a second interlocking joint (400) is created by inserting a pin (402) into a passageway (401) formed between two adjacent second radial interlocking profiles (112, 212).