Multifunctional Modular Truss: Structural Design, Material Selection, and Installation Process Guided by the core design concept of "flexible combination and multi-scenario adaptability," the multifunctional modular Truss integrates standardized modules with expandable structures.It balances load-bearing performance and operational flexibility, making it widely applicable in performances, exhibitions,Modular Truss temporary buildings, and other fields. Details of its structural design, material selection, and installation process are as follows: I. Structural Design: Modular Combination for Multi-Dimensional Adaptability
The overall design adopts a layered structure of "standardized basic modules + functional expansion components," which not only ensures universal splicing but also meets scenario-specific needs. modular truss system Key structural features are as follows: 2. Basic Modules: Standardization and Universality
Unified Module Specifications: Basic truss units follow standardized dimensions, with common lengths of 1m/2m/3m (customizable to 6m on demand). Cross-sections are mostly triangular (200mm×200mm) or square (300mm×300mm), Lightweight Round Tube Truss compatible with industry-standard connectors. Modules from different batches or for different scenarios can be interchangeably spliced, eliminating the limitation of "one design per scenario." Quick-Connect Joint Structure: Each module end is equipped with a dual-connection joint of "flange + latch":
Flanges enable precise positioning Modular Round Tube Truss (with locating pin holes, deviation ≤1mm) and are fixed with 4-6 high-strength bolts to ensure load-bearing stability; Latch-type auxiliary connections (locked by rotation after insertion) allow quick preliminary splicing, Structural Round Tube Truss operable by a single person, significantly improving assembly efficiency. Pre-Reserved Expansion Interfaces: One set of standardized interfaces (12-16mm aperture with internal threads) is arranged every 0.5m on the side of basic modules. These interfaces can directly mount equipment such as lighting, audio, and exhibition props without additional welding or drilling, adapting to functional needs of performances, exhibitions, etc.
2. Expansion Components: Scenario-Specific Functional Supplements
Load-Bearing Enhancement Components: Versatile Modular Truss Design Innovative Modular Truss System For large-span or heavy-load scenarios (e.g., suspending large LED screens), "reinforced diagonal web members" (30°-45° angle with basic modules, same material as the main truss) and "anti-overturning bases" (with counterweight slots for sandbags or concrete blocks) can be added. This increases the rated load of a single truss from 300kg to 800kg.
Shape Adjustment Components: Include "corner modules" (90° right angle/135° obtuse angle) and "arc modules" (customizable curvature radius for circular stages or annular exhibition stands). These parts can help join linear trusses together to form complex shapes, like L-shapes, U-shapes, and ring-shapes. That way, they can fit in with irregular site layouts.
Auxiliary Functional Components: Support "cable storage channels" (attached to truss sides for hiding power cables and signal cables), "safety barrier interfaces" (for installing guardrails on temporary stand trusses), and "sunshade/rain shelter connectors" (for shelter roof construction in outdoor scenarios), Customizable Modular Truss Kits realizing integrated integration of "truss + functional accessories."
II. Material Selection: Balancing Lightweight and Durability
Material selection prioritizes high-strength, easy-to-process materials to meet dual needs of "modular handling convenience" and "long-term operational reliability." Key material characteristics are as follows:
1. Main Material: Aviation-Grade Aluminum Alloy as the Mainstream
Base Material Selection: Over 90% of scenarios use 6061-T6 aluminum alloy, Durable Aluminum Truss System which has a tensile strength of ≥260MPa and yield strength of ≥240MPa. It not only meets load-bearing requirements for small-to-medium loads (e.g., lighting, exhibition props) but also offers lightweight advantages: a 2m-long truss module with a 200mm×200mm cross-section weighs only 8-12kg, easily portable by an adult without large hoisting equipment. Surface Treatment Process: All aluminum alloy components undergo dual treatment of "anodization + electrostatic spraying":
Anodization forms a 10-15μm thick oxide film to improve corrosion resistance of the base material;
Electrostatic spraying uses weather-resistant powder coatings (customizable colors, commonly silver and black) with a thickness of ≥60μm, which can withstand outdoor sun exposure and rain (stable performance in -30℃ to 60℃ environments). With proper maintenance, the service life reaches 8-10 years.
Materials for Special Scenarios: For industrial heavy-load scenarios (e.g., temporary load-bearing frames in factories), the main material uses Q235 low-carbon steel (hot-dip galvanized surface with zinc layer thickness ≥85μm). A single truss can bear 1-2t, meeting suspension needs for heavy equipment.
2. Connector Materials: High-Strength Supporting Materials
Bolts and Latches: Bolts use 8.8-grade high-strength carbon steel (galvanized surface for rust prevention) with a torque bearing capacity of ≥40N・m, avoiding thread slippage due to long-term assembly and disassembly; latches are made of 45# steel with quenching and tempering treatment (hardness HRC28-32), paired with spring buckles to prevent loosening from vibration.
Flanges and Interface Parts: Flanges use die-cast aluminum alloy (ADC12) with an accuracy of IT12 grade, ensuring precise positioning during module splicing; expansion interface parts (e.g., equipment hangers, guardrail connectors) use stainless steel (304 material) with strong corrosion resistance, suitable for humid or outdoor scenarios.
III. Installation Process: Modular Splicing for Low-Threshold Operation
Relying on standardized modules and quick-connect structures, installation requires no professional welders or complex equipment and can be completed by a 2-4-person team. Key steps are as follows:
1. Pre-Installation Preparation and Planning
Site Survey: Confirm the flatness of the installation area (slope ≤3°), clear debris, mark the truss layout with a tape measure (e.g., for building a 10m×5m exhibition truss, 5 pieces of 3m basic modules + 2 pieces of 1m basic modules + 4 corner modules are needed), and mark the base positions with chalk.
Component Inventory and Inspection: Check the quantity of basic modules, expansion components, and connectors (following the ratio of "1 set of connectors per set of basic modules"). Inspect for no deformation on module surfaces, no damage to interfaces, and no rust on bolts or latches.
2. Basic Frame Construction (Taking a 10m×5m Exhibition Truss as an Example)
Step 1: Fix the Bases: Place adjustable bases (height adjustment range 0.3-0.8m) at marked positions. Adjust the screws using the level bubble on the base top to ensure all base tops are on the same horizontal plane (deviation ≤2mm) for improved overall stability.
Step 2: Splice Basic Modules: Two people form a group to carry basic modules, align the flange at the module end with the base flange, insert the locating pin, and fix with 4 bolts (tightened to 35-40N・m using a torque wrench to ensure firmness). First splice the longitudinal main frames (2 pieces of 10m-long frames, composed of 3m+3m+3m+1m modules), then splice the transverse frames (5 pieces of 5m-long frames, composed of 3m+2m modules).
Step 3: Install Expansion Components: Install reinforced diagonal web members (1 set per 3m span, 45° angle with the main frame, fixed with bolts) and corner modules (installed at frame corners to ensure interface fitting) as needed. If equipment mounting is required, install equipment hangers at pre-reserved interfaces (directly screwed into threaded interfaces without additional tools).
3. Safety Inspection and Debugging
Structural Stability Inspection: Manually shake the truss to test lateral displacement resistance, recheck the frame levelness with a level, and ensure all bolts are tightened and latches are locked with no looseness.
Functional Adaptation Debugging: If lighting or exhibition props are mounted, test the load-bearing capacity of equipment mounting points (single-point load ≤80% of the module’s rated load to avoid overloading). Adjust the cables in the cable storage channels to ensure no tangling or extrusion. The entire installation process (including expansion components and equipment mounting) takes approximately 3-4 hours.
4. Disassembly Process
Follow the reverse operation: first remove all mounted equipment and expansion components, loosen bolts and pull out latches to disassemble basic modules, then 收起 the bases, and finally sort and place components into dedicated storage boxes (basic modules can be stacked, with a maximum stacking height of 1.5m for 2m modules). Disassembly of a 10m×5m truss can be completed within 1-2 hours, and modules can be reused in subsequent scenarios.
Wuxi Zhongshengwei Metal Products Co., Ltd.
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