How does PLUCC work?
PLUCC is not only used in vehicle construction, it can also be used wherever fast or simple connections of elements or assemblies are required.
Such a requirement can exist, for example, in building construction or bridge construction.
With the help of PLUCC , pre-assembled modules can be joined together in just a few steps.
For bridge construction, the system for assembling rod-shaped components as well as for road segments would be conceivable.
The size of the connecting elements can be adapted to the dimension of the components to be connected.
In the case of lane segments for a multi-lane bridge, the connecting parts can have cubic meters in size.
Technical applications
With the PLUCC connection system, at least two components are positively inserted into one another and then connected with a screw-type connection in accordance with the necessary rigidity.
The system is then ready for immediate use and can withstand all previously designed load cases.
In the event of disassembly, the plug-in system can be reinstalled to its original condition without loss of rigidity.
In principle, any components of different topology can be put together depending on the desired body.
A system with PLUCC connections can be understood as a modular system, whereas it is possible for individual assemblies to be made up of interchangeable components.
However, all replaceable components are provided with the same PLUCC connection.
Use of 3D printing technology for production
The use of 3D printing technology for PLUCC would be ideal, but is currently only available to a limited amount of components even according to the latest technical standards.
With the use of 3D printing, the application of the PLUCC system would achieve even greater flexibility.
To verify the PLUCC technology, the 3Pman GmbH got made a 3D print model in order to check basic functions as well as assembly handling and structural loads.
Special load cases were analysed in order to get statements regarding different topologies.
The video stream shows a small selection of selected load cases. The other images of the 3D print model reflect the exemplary design, which has gone through further development steps to present.
PLUCC-Structure
Branching
Contact pressure under operational load
Experimental 3D Print Model
Experimental 3D Print Model
PLUCC-Bridge Concept
Analysis results under operational load
CAD 3D-Print-Model
CAD 3D-Print-Model
Material design
In order to be able to move large components with manageable effort on construction sites on the ground or in building construction, these should be as light as possible.
The PLUCC connection system can be constructed from metallic as well as fiber composite materials, whereby individual components can consist of material combinations.
This means that the connecting elements can be significantly reduced in terms of mass through constructive and lightweight material construction.
Plastic-based materials can be combined with suitable metal materials.
As a result, provisions to increase rigidity and strength must be implemented.
Lean structures must be designed to prevent buckling and folding, but stress peaks must be avoided in terms of concentrated force application.
It is possible to determine lightweight construction indicators that determine the best material in terms of density for special load cases.
Here, the fiber composite materials usually achieve the best values, but are often not shortlisted due to the high costs.
Corrosion also plays a role that should not be underestimated when considering material selection.
The progress of weakening the structure due to corrosion also determines maintenance intervals that should be as large as possible.
Access to areas susceptible to corrosion must also be considered from the beginning of the development so as not to end in costly repair measures.
Principles of construction
Even if light materials are used, constructive solutions must be developed that meet the above-mentioned conditions against failure.
To be able to design lightweight construction efficiently, several basic design principles must be observed and implemented.
- Avoidance of unfavorable direct force application and the choice of direct load paths to avoid undesired additional moments
- If possible, choose large-area load transfer, e.g. with a transverse load on profiles. This significantly reduces the maximum deformation as well as the bending moment.
- Transfer of transverse loads to bearings (supports) directly below. This allows the bending moment to reduce to zero if applicable
- Choosing closed profiles is preferable to open profiles. This applies above all to torsion loads, but also to shear loads outside the profile cross-section Closed profiles are significantly more torsion-resistant.
- Choosing hollow profiles in the case of transvers load compared to solid profiles is favorable, since the moments of inertia against bending deformation should be as far as possible from the surface center of gravity. On the other hand, the webs of the profile take over the shesr that occurs during bending
- Plate bending can be reduced in a similar way. Here, the plate, which is subjected to shear force, should have two outer skins with a core placed between