Weld-Free Tunnel Ceiling Suspension with Ball Socket Joint
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Solution Overview
Problem
Existing suspended fastening devices for intermediate ceilings in tunnels require high structural effort and weld seams, which are costly, difficult to manufacture, and prone to failure under dynamic loads, limiting their use in renovations and new constructions.
Innovation Solution
A device with a rod connected to a top plate without welds, using a screw connection with an external thread and a ball socket mechanism for flexibility, allowing for easy production, installation, and load absorption, enabling attachment to existing ridges and flexible positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the intermediate ceiling is positioned at the edge or without intermediate suspension, then the static requirements are met, but a lot of material is required and costs increase
Solution Approach 1:
The ceiling structure is divided into segments suspended at intermediate positions rather than requiring a continuous thick ceiling. The suspension device divides the load-bearing function into discrete points (head plate at ridge, anchor plate at ceiling), allowing the ceiling material itself to be thinner while maintaining overall structural strength.
2Strength
If the false ceiling is designed with large thickness, then static requirements are met, but material costs and construction costs increase
Solution Approach 1:
The load-bearing function is segmented from the ceiling material to a separate suspension device. This allows the ceiling to be manufactured as a thinner, less expensive element while the suspension device (with its ball socket joint and rod) carries the structural load, reducing overall construction costs.
3Strength
If the intermediate body is welded to the headstock, then connection strength is achieved, but weld seams are prone to failure under dynamic loads and require complex testing
Solution Approach 1:
The rigid weld connection is replaced with a dynamic ball socket joint that allows controlled movement and rotation. This dynamic connection absorbs dynamic loads through the ball-and-socket mechanism rather than transmitting stress to a rigid weld seam, improving reliability under varying load conditions while eliminating welding requirements.
Solution Approach 2:
The ball socket joint acts as an intermediary element between the head plate and the rod. This intermediary mechanism provides the necessary connection strength while accommodating dynamic movements, replacing the need for weld seams and their associated testing requirements.
4Stability of the object's composition
If devices are concreted into the ridge at the head end, then structural stability is achieved, but structural effort increases and renovation becomes impossible
Solution Approach 1:
The stabilization function is segmented from the ridge structure to a separate head plate that attaches to the ridge surface. This allows the ridge to remain intact (important for renovations) while the head plate provides stable attachment points for the suspension device through its ball socket joint.
Solution Approach 2:
The static concrete embedding is replaced with a dynamic attachment system using the head plate and ball socket joint. This provides sufficient structural stability through mechanical attachment without requiring concrete work, reducing structural effort and enabling renovation applications.
5Strength
If the rod is connected to the top plate with weld seams, then connection strength is achieved, but production complexity and testing requirements increase
Solution Approach 1:
The weld connection is replaced with a threaded rod that engages with the head plate through the ball socket joint. This intermediary threaded connection provides sufficient strength while being much simpler to manufacture, as it requires only threading operations rather than welding and subsequent testing.
Data Source
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AI summary
The invention relates to a device (1) for the suspended attachment of an intermediate ceiling (4) to a ridge (3) of a tunnel (2), comprising a head plate (5) that can be attached to the ridge (3) by means of fasteners (6), a rod (8) and an anchor plate (7) for attaching the intermediate ceiling (4), wherein the head plate (5) and the anchor plate (7) are connected via the rod (8). According to the invention, the rod (8) is held on the head plate (5) without welds.