Terrace Canopy Beam Alignment Using Tongue-and-Groove Corners
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Solution Overview
Problem
Existing terrace canopies face issues with beam misalignment and instability under high loads, such as excessive wind and precipitation, due to manufacturing tolerances in the connection between beams and support pillars, leading to potential collapse.
Innovation Solution
The implementation of mutually cooperating alignment means, specifically a tongue and groove system, to ensure precise alignment of beams with respect to the support pillar, reducing horizontal shifts and rotational errors during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional connection methods (screws, bolts, L-shaped corner pieces) are used to connect beams to support pillars, then the structure can be assembled, but manufacturing tolerances cause beam misalignment and horizontal shifts, leading to instability under high loads
Solution Approach 1:
The patent introduces a corner element as an intermediary component between the beam headboard and the support pillar. This corner element features a tongue-and-groove alignment system where the tongue on the corner element fits into a groove on the headboard, providing precise alignment and eliminating misalignment issues caused by conventional direct connection methods.
Solution Approach 2:
The alignment means (tongue-and-groove system) are pre-formed on the corner element and headboard during manufacturing. This preliminary alignment feature ensures that when the components are assembled, the beam is automatically positioned correctly relative to the support pillar, preventing horizontal shifts and rotational errors before loading occurs.
2Ease of operation
If standard connection components are used, then assembly is straightforward, but the connection allows horizontal shifts and rotational errors due to tolerance accumulation
Solution Approach 1:
The corner element serves as a mediator that incorporates the alignment function. The tongue-and-groove mechanism is built into this intermediary component, allowing workers to assemble the structure using simple steps while the alignment features automatically ensure high precision connection accuracy without requiring complex adjustment procedures.
3Ease of manufacture
If the connection structure is simplified, then manufacturing is easier, but the connection cannot withstand high loads from wind and precipitation
Solution Approach 1:
The connection structure is segmented into distinct functional components: the headboard on the beam, the corner element with alignment features, and the support pillar. This segmentation allows each component to be manufactured independently using standard processes, while the tongue-and-groove interface between them provides the necessary strength to withstand high loads from wind and precipitation.
Solution Approach 2:
The corner element as an intermediary not only provides alignment but also serves as a load transfer component. The multiple contact surfaces and the tongue-and-groove interface distribute and transfer loads effectively from the beam through the corner element to the support pillar, maintaining high load-bearing capacity without complicating the manufacturing of individual components.
Data Source
AI summary
The disclosure provides a terrace canopy comprising a support pillar extending in a substantially vertical direction; a first and a second beam each extending in a substantially horizontal direction, wherein each beam is provided with a headboard at at least one end; and a corner element positioned between and secured to the support pillar and the beams and provided with a first and a second wall portion. The headboard of the first beam is attached against the first wall portion of the corner element, and the headboard of the second beam is attached against the second wall portion of the corner element. Mutually cooperating alignment means comprising a tongue and groove are provided between each wall portion and the headboard attached thereto, the mutually cooperating alignment means being configured for aligning a beam with respect to the support pillar.