Sway Brace Attachment with Segmented Insert and Set Screws
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Solution Overview
Problem
Existing sway brace attachments for bracing pipes and loads below floors and ceilings lack the ability to withstand substantial loads, are not easily adjustable, and are not economical in both manufacturing and use, while also being limited in their compatibility with various beam types and sizes.
Innovation Solution
A sway brace attachment featuring a main body with an insert and set screws that securely grip flanged structures, allowing for adjustable and economical installation on a wide range of flanged surfaces, including I-beams, H-beams, and channels, with set screws designed to break off at a threshold torque for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing sway brace attachments are used, then installation is relatively simple, but load-bearing capacity is insufficient and adjustability is limited
Solution Approach 1:
The attachment device is divided into multiple functional segments: a U-shaped body for mounting, an insert for engagement, and multiple set screws for fastening. This segmentation allows each component to be optimized independently for strength while maintaining overall simplicity of assembly.
Solution Approach 2:
The insert is positioned within the U-shaped body, creating a nested structure where the insert fits into the body's opening. This nested configuration increases load-bearing capacity by distributing forces through multiple contact surfaces while adding minimal structural complexity.
2Strength
If sway brace attachment is designed for heavy load capacity, then strength is improved, but manufacturing cost and installation complexity increase
Solution Approach 1:
By segmenting the attachment into a simple U-shaped body and a separate insert, each component can be manufactured using basic forming and machining processes. This segmentation avoids the need for complex single-piece machining or welding operations, reducing manufacturing costs while achieving high load capacity through the combined structure.
Solution Approach 2:
The insert provides localized reinforcement at the critical engagement point with the flange, while the U-shaped body maintains a simple, lightweight structure. This local quality approach concentrates material and strength where needed without increasing overall manufacturing complexity or cost.
3Adaptability or versatility
If sway brace attachment uses fixed design, then manufacturing is simple, but adaptability to various flanged structures is limited
Solution Approach 1:
The attachment transitions from a fixed design to a dynamically adjustable design through the inclusion of multiple set screws that can be positioned at different locations and tightened to different degrees. This allows the same attachment to adapt to various flange sizes, shapes, and orientations without requiring multiple specialized designs.
Solution Approach 2:
The U-shaped body with its open configuration and the insert with multiple engagement points create a universal attachment that can accommodate various flanged structures including I-beams, H-beams, and channels. The same basic design serves multiple functions across different applications without requiring modification.
4Reliability
If multiple set screws and insert are used, then connection reliability is improved, but assembly time and complexity increase
Solution Approach 1:
The insert is pre-positioned within the U-shaped body during manufacturing, and the set screw holes are pre-drilled and threaded. This preliminary action ensures proper alignment during installation, allowing the attachment to be quickly assembled by simply inserting the device onto the flange and tightening the set screws without requiring complex alignment procedures.
Solution Approach 2:
By segmenting the fastening system into multiple set screws that can be tightened independently, the attachment achieves high connection reliability through distributed fastening points. This segmentation allows installers to work on multiple screws simultaneously or in sequence without requiring complete disassembly and reassembly, reducing overall installation time.
Data Source
AI summary
A sway brace attachment for firmly connecting to a beam and other flanged structures, and a method for manufacturing the sway brace attachment. The sway brace attachment includes a main body and an insert that is captured within the main body by a pair of set screws which also engage the flange. Preferably, a third set screw is supported by the main body and engages the opposite side of the flange from the pair of set screws. The main body can be generally rectangular in shape, with a top wall, a pair of side walls extending from the top wall and a pair of bottom walls, which extend inwardly from respective side walls in an overlapping relationship. The sway brace attachment can be used for bracing pipes and other loads, suspended below ceilings and floors, against sway and seismic disturbances.