Stage Floor Assembly Self-Aligning Grid Network
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Solution Overview
Problem
Existing stage floor assembly methods are inefficient due to mistaken nodal assembly theories, leading to substantial time in assembly, low strength-to-weight ratio, and significant deflection under loading, as they rely on elongated members terminating at each node without connecting three adjacent pedestals.
Innovation Solution
A stage floor assembly featuring a plurality of pedestals with stringers that terminate at each pedestal and one stringer crossing two rods, forming a grid network that self-aligns on uneven surfaces, distributing loads across pedestals and using angular supports to maintain structural integrity and resist explosive blasts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If elongated members terminate at each node without connecting three adjacent pedestals, then assembly is simpler, but strength-to-weight ratio is low and deflection is significant
Solution Approach 1:
The floor system is segmented into modular units with pedestals spaced at intervals, allowing independent assembly of each module. Stringers connect three adjacent pedestals within each module, creating self-contained structural units that are easy to manufacture and assemble while maintaining high strength-to-weight ratio through the continuous stringer design.
Solution Approach 2:
The patent merges the functions of multiple stringers by having a single stringer connect three adjacent pedestals simultaneously. This combines the structural support function across multiple bays, eliminating the need for separate stringers between each pedestal pair, thereby improving strength-to-weight ratio while simplifying assembly.
2Loss of time
If elongated members terminate at each node, then assembly time is reduced, but deflection under loading is significant
Solution Approach 1:
The stringers are designed to extend continuously through multiple pedestal locations in advance, rather than being assembled in separate segments. This preliminary continuous design prevents deflection under loading while the modular pedestal spacing allows for rapid assembly, reducing time loss without compromising structural stability.
Solution Approach 2:
The stringers provide continuous structural support across multiple pedestals rather than terminating at each node. This continuity of the load-bearing element prevents deflection under loading while the modular nature of the pedestal-stringer-pedestal units maintains fast assembly time.
3Strength
If stringers connect three adjacent pedestals continuously, then strength-to-weight ratio improves, but assembly complexity increases
Solution Approach 1:
The continuous stringer design is segmented into modular units defined by pedestal locations. Each module contains a stringer section connecting three pedestals, which can be manufactured and assembled independently. This segmentation reduces assembly complexity while maintaining the strength benefits of continuous stringers across each module.
Solution Approach 2:
The stringer design serves multiple functions simultaneously: it connects three adjacent pedestals for structural support, spans multiple bays for load distribution, and forms part of a modular assembly unit. This multi-functionality reduces the need for additional components, simplifying assembly while maintaining high strength-to-weight ratio.
4Ease of operation
If pedestals are arranged in rows with stringers transiting between them, then assembly is straightforward, but deflection control is poor
Solution Approach 1:
The patent merges the support function across multiple rows by having stringers connect three adjacent pedestles in a continuous path. This combines the load-bearing capacity across what would otherwise be separate row segments, preventing deflection while maintaining the straightforward row-based assembly approach.
Solution Approach 2:
The stringer design extends into a third dimension by connecting pedestals across multiple rows and bays simultaneously, rather than merely transiting between adjacent pedestals in a single row. This dimensional extension provides deflection control while preserving easy assembly through the modular nature of the connections.
Data Source
AI summary
A stage floor assembly can be easily assembled, aligned and adjusted even on an uneven surface. The stage floor assembly includes a plurality of pedestals with each pedestal further comprising a pedestal base attached to a plurality of rods. There is a plurality of stringers placed upon some of the plurality of rods such that two stringers terminate at each pedestal and one stringer crosses two rods on each pedestal forming a grid network that self-aligns even on the uneven surface. A plurality of deck plates is attached to the plurality of stringers creating a surface to absorb and distribute loads across pedestals preventing noticeable deflection across the stage floor assembly.