Machining tool positioning system for hollow component

Abstract

To provide: a machining tool positioning system with no need for a human operator to access a hollow area; and a machining system.SOLUTION: A machining tool positioning system includes a post configured to be rotatably mounted relative to a hollow component to be machined. A base member is slidingly mounted relative to the post. A first actuator is configured to selectively slidingly move the base member relative to the post. A tool slide rail is coupled to the base member and extends perpendicularly to the post. A machining tool slide mount is slidingly coupled to the tool slide rail and configured to position a machining tool relative to the rail. A second actuator is coupled at a first end to the base member and coupled at a second end to the machining tool slide mount, and configured to selectively move the machining tool slide mount along the rail.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates generally to machining systems, and more particularly to a machining tool positioning system and machining system for hollow components, such as control valve casings, as claimed. [Background technology]

[0002] Large industrial components can develop cracks after extended use. These cracks can be repaired by removing the crack, replacing the removed material with buildup or welding, and repairing the crack. In some industrial components, cracks develop over time in difficult-to-access locations, such as on surfaces inside hollow components. An example of a hollow component is a large main steam stop valve and control valve casing for a steam turbine, which may include an upper chamber fluidly coupled to a lower chamber. The upper and lower chambers each include steam inlet and outlet openings and component openings for the control valve body. The upper and lower chambers also include various surfaces that may be susceptible to cracking after extended use. To machine a surface inside the valve casing, the control valve body is removed from the valve casing, and a human machine operator with a machining tool enters the hollow region within one or more of the chambers to access the surface to be machined. Entering one or more hollow regions can be a very uncomfortable and cramped position for the operator. Summary of the Invention

[0003] The inventions claimed herein are set forth in the accompanying claims.

[0004] All aspects, embodiments and features described below can be combined in any technically possible manner.

[0005] Aspects of the present disclosure include a processing system for a hollow component, the processing system including: a support column configured to be rotatably mounted relative to the hollow component; a base member slidably mounted relative to the support column; a first actuator fixedly coupled to the support column at a first end and coupled to the base member at a second end, the first actuator configured to selectively slidably move the base member relative to the support column; a tool slide rail coupled to the base member and extending perpendicular to the support column; a processing tool slide mount slidably coupled to the tool slide rail; a second actuator coupled to the base member at a first end and coupled to the processing tool slide mount at a second end, the second actuator configured to selectively move the processing tool slide mount along the tool slide rail; and a processing tool coupled to the processing tool slide mount.

[0006] Another aspect of the present disclosure includes any of the aforementioned aspects, wherein the base member includes a base plate having a first end and a second end, a base slide rail fixedly coupled to the support column, and a slide mount slidably coupling the base plate to the base slide rail, the support column including an attachment end rotatably attached to the hollow component, and the slide mount selectively and slidably attaches the base plate to the base slide rail in either a first position where the first end of the base plate faces the attachment end of the support column, or a second position where the second end of the base plate faces the attachment end of the support column.

[0007] Another aspect of the present disclosure includes any of the above aspects, further comprising a motor fixed relative to the hollow component and operatively coupled to the post to selectively rotate the post, the base member, and the processing tool relative to the hollow component.

[0008] Another aspect of the present disclosure includes any of the aforementioned aspects, wherein the first actuator includes a single double-acting linear actuator and the second actuator includes a retraction linear actuator and an extension linear actuator.

[0009] Another aspect of the present disclosure includes any of the aforementioned aspects, wherein the processing tool slide mount includes an adjustable mount configured to selectively position the processing tool at a plurality of angular positions relative to the hollow component.

[0010] Another aspect of the present disclosure includes any of the above aspects, further comprising a control system for controlling the first and second actuators and the processing tool.

[0011] Another aspect of the present disclosure includes any of the above aspects, further comprising a motor fixed relative to the hollow component and operatively coupled to the post to selectively rotate the post, the base member, and the processing tool relative to the hollow component.

[0012] Another aspect of the present disclosure includes any of the above aspects, further comprising a control system for controlling the first and second actuators, the motor, and the processing tool.

[0013] Another aspect of the present disclosure includes any of the aforementioned aspects, wherein the control system includes a computer numerically controlled (CNC) controller configured to control operation of the first and second actuators, the motor, and the processing tool, and the first and second actuators each include a stepper motor.

[0014] Another aspect of the present disclosure includes any of the above aspects, further comprising at least one camera positioned relative to the support post to film operation of the processing tool, and a video display configured to display images from the at least one camera.

[0015] Another aspect of the present disclosure includes any of the aforementioned aspects, further comprising a digital position estimation system configured to sense a position of the processing tool in three-dimensional space.

[0016] Another aspect of the present disclosure includes any of the above aspects, further comprising a bushing configured to rotatably mount the post relative to the hollow component.

[0017] Aspects of the present disclosure include a processing tool positioning system including: a support column configured to be rotatably mounted relative to a hollow component to be processed; a base member slidably mounted relative to the support column; a first actuator fixedly coupled to the support column at a first end and coupled to the base member at a second end, the first actuator configured to selectively slidably move the base member relative to the support column; a tool slide rail coupled to the base member and extending perpendicular to the support column; a processing tool slide mount slidably coupled to the tool slide rail, the processing tool slide mount configured to position a processing tool; and a second actuator coupled to the base member at a first end and coupled to the processing tool slide mount at a second end, the second actuator configured to selectively move the processing tool slide mount along the tool slide rail.

[0018] Another aspect of the present disclosure includes any of the aforementioned aspects, wherein the base member includes a base plate having a first end and a second end, a base slide rail fixedly coupled to the support column, and a slide mount slidably coupling the base plate to the base slide rail, the support column including an attachment end rotatably attached to the hollow component, and the slide mount selectively and slidably attaches the base plate to the base slide rail in either a first position where the first end of the base plate faces the attachment end of the support column, or a second position where the second end of the base plate faces the attachment end of the support column.

[0019] Another aspect of the present disclosure includes any of the above aspects, further comprising a motor fixed relative to the hollow component and operatively coupled to the post to selectively rotate the post, the base member, and the processing tool relative to the hollow component.

[0020] Another aspect of the present disclosure includes any of the aforementioned aspects, wherein the first actuator includes a single double-acting linear actuator and the second actuator includes a retraction linear actuator and an extension linear actuator.

[0021] Another aspect of the present disclosure includes any of the aforementioned aspects, wherein the processing tool slide mount includes an adjustable mount configured to selectively position the processing tool at a plurality of angular positions relative to the hollow component.

[0022] Another aspect of the present disclosure includes any of the above aspects, further comprising a motor fixed relative to the hollow component and operatively coupled to the post to selectively rotate the post, the base member, and the processing tool relative to the hollow component.

[0023] Another aspect of the present disclosure includes any of the aforementioned aspects, further comprising a control system for controlling the first and second actuators and the motor, the motor being fixed relative to the hollow component and operatively coupled to the support post to selectively rotate the support post, the base member, and the processing tool relative to the hollow component.

[0024] Another aspect of the present disclosure includes any of the aspects above, further comprising a digital position estimation system configured to sense a position of the processing tool in three-dimensional space, wherein the control system includes a computer numerically controlled (CNC) controller configured to control operation of the first and second actuators and the motor, and wherein the first and second actuators each include a stepper motor.

[0025] Two or more aspects described in this disclosure, including those described in the Summary of the Invention above, may be combined to form an embodiment not specifically described herein, i.e., all embodiments described herein can be combined with each other.

[0026] The details of one or more embodiments are set forth in the accompanying drawings and the following description. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

[0027] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings illustrating various embodiments of the disclosure. [Brief explanation of the drawings]

[0028] [Figure 1] FIG. 1 is a cross-sectional perspective view illustrating an exemplary hollow component that may employ a processing tool positioning system and a processing system according to embodiments of the present disclosure. [Figure 2] FIG. 1 is a perspective view illustrating a first side of a processing tool positioning system and a processing system according to an embodiment of the present disclosure. [Figure 3] FIG. 10 is a perspective view illustrating a second side of a processing tool positioning system and a processing system according to an embodiment of the present disclosure. [Figure 4] 1 is a cross-sectional view illustrating an exemplary arrangement of slide rails and slide mounts according to an embodiment of the present disclosure. FIG. [Figure 5] 4 is a perspective view illustrating a processing tool positioning system and a processing system in a different position than in FIGS. 2-3 according to an embodiment of the present disclosure. FIG. [Figure 6] FIG. 10 is an exploded perspective view illustrating an optional adjustment mount according to an embodiment of the present disclosure. [Figure 7] 1 is a partial cross-sectional view illustrating a processing tool positioning system and processing system according to an embodiment of the present disclosure during operation within a hollow component. FIG. [Figure 8]FIG. 1 is a perspective view illustrating a processing tool positioning system and a control system for a processing system according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0029] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered limiting of the scope of the disclosure. In the drawings, like reference numerals represent like elements between the drawings.

[0030] As an initial matter, a clear explanation of the subject matter of the present technology will require the selection of certain terminology when referring to and describing the process tool positioning system and related machine components within an exemplary application of the process system. In doing so, common industry terminology will be used and employed, whenever possible, consistent with their accepted meaning. Unless otherwise noted, such terminology should be given a broad interpretation consistent with the context of this application and the appended claims. Those skilled in the art will recognize that particular components are often referred to using several different or overlapping terms. What may be described herein as a single part may, including and in other contexts, be referred to as consisting of multiple components. Alternatively, what may be described herein as including multiple components may be referred to elsewhere as a single part.

[0031] Additionally, several descriptive terms may be used frequently herein, and it may prove useful to define these terms at the beginning of the detailed description. These terms and their definitions, unless otherwise specified, are as follows: The term "axial" refers to movement or position parallel to an axis, e.g., the axis of a mechanical component. The term "radial" refers to movement or position perpendicular to an axis, e.g., the axis of a mechanical component. In such cases, if a first component is closer to the axis than a second component, the first component is said to be "radially inward" or "inside" the second component. Conversely, if a first component is farther from the axis than the second component, the first component is said to be "radially outward" or "outside" the second component. Finally, the term "circumferential" refers to movement or position around an axis, e.g., a circular mechanical component.

[0032] In addition, several descriptive terms may be frequently used in this specification, as described below: The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to imply the location or importance of the individual components.

[0033] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the disclosure. As used herein, the singular articles "a," "an," and "the" are intended to include the plural unless the context clearly dictates otherwise. It will be further understood that the terms "comprises" and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optional" or "optionally" means that the subsequently described event may or may not occur, or that the subsequently described feature may or may not be present, and that the description includes instances in which the event occurs or the feature is present as well as instances in which the event does not occur or the feature is not present.

[0034] When an element or layer is referred to as being "on," "engaged to," "connected to," "coupled to," or "mounted to," the element or layer may be directly on, engaged with, connected to, coupled to, or attached to another element or layer, or there may be intervening elements or layers. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to," there are no intervening elements or layers. Other words used to describe relationships between elements should be interpreted similarly (e.g., "directly between" for "between" and "directly adjacent" for "adjacent"). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. The verb forms "couple" and "mount" may be used interchangeably herein.

[0035] An embodiment of the present disclosure includes a processing tool positioning system. The system includes a support column configured to be rotatably mounted relative to a hollow component to be machined. A base member is slidably mounted relative to the support column, and a first actuator is fixedly coupled to the support column at a first end and coupled to the base member at a second end. The first actuator is configured to selectively slidably move the base member relative to the support column. A tool slide rail is coupled to the base member and extends perpendicular to the support column. A processing tool slide mount is slidably coupled to the tool slide rail and configured to position the processing tool. A second actuator is coupled to the base member at a first end and coupled to the processing tool slide mount at a second end. The second actuator is configured to selectively move the processing tool slide mount, and therefore the processing tool, along the tool slide rail. A motor may optionally change the orientation of the support column to rotate the position of the base member and the processing tool. The processing system includes the processing tool positioning system and also includes a processing tool. The system provides for remotely machining hollow areas of large hollow components, e.g., hollow areas large enough for a person to fit at least a portion of the hollow component. The system thereby eliminates the need for a human worker to access the hollow area inside the hollow component to perform repairs. The system is precise, lightweight, portable, and adjustable to fit hollow components of different shapes and sizes.

[0036] FIG. 1 is a cross-sectional perspective view illustrating an exemplary hollow component 100 that may employ a machining tool positioning system and machining system according to embodiments of the present disclosure. In the illustrated example, the hollow component 100 is a casing 102 for a large main steam stop and control valve for a steam turbine (not shown). The casing 102 includes an upper chamber 104 that is fluidly coupled to a lower chamber 106. The upper and lower chambers 104, 106 may each include steam inlet and outlet openings 108, 110 and openings 112, 114 for components of a control valve body (not shown). The upper and lower chambers 104, 106 also include various surfaces 116 that may be prone to cracking after extended use. As described above, to machine the surfaces 116 within the casing 102, the control valve body (not shown) is removed from the valve casing 102, and a human machine operator with a machining tool enters the hollow region within one or more of the chambers 104, 106 to access the surfaces 116 to be machined. This arrangement can put a human operator in a very uncomfortable and cramped position. To avoid this situation, embodiments of the present disclosure provide a processing tool positioning system and processing system that does not require a human operator to access hollow areas.

[0037] FIG. 2 is a perspective view showing a first side of the processing system 120 and processing tool positioning system 122 for the hollow component 100 ( FIG. 1 ), and FIG. 3 is a perspective view showing a second side of the processing system 120 and processing tool positioning system 122 for the hollow component 100 ( FIG. 1 ). The processing system 120 and processing tool positioning system 122 (hereinafter referred to as “systems 120, 122” unless otherwise required) include a support 130 ( FIG. 3 only) configured to be rotatably mounted relative to the hollow component 100. The support 130 may include any form of metal or alloy structural member. While the support 130 is illustrated as a cylindrical element, its cross-section may be any shape (partially or entirely) as long as it is rotatable relative to the hollow component 100. The support 130 includes a first end 132 and a second end, a mounting end 134, opposite the first end 132. The mounting end 134 is configured to be rotatably mounted relative to the hollow component 100. The mounting end 134 may be rotatably positioned relative to the hollow component 100 in any manner now known or later developed. In the example shown in FIG. 3, the mounting end 134 is rotatably coupled to the hollow component 100 by a bushing 136 that fits into an opening, such as the valve body opening 114 ( FIG. 1 ), in the casing 102 ( FIG. 1 ). However, other forms of rotatably mounting the mounting end 134 are possible, such as being positioned in a corresponding hole in the hollow component 100 without a bushing or using another form of rotational support element within or coupled to the hollow component 100.

[0038] Systems 120, 122 also include a base member 140 that is slidably mounted relative to support post 130. Base member 140 may include any now known or later developed structural element that is movable relative to support post 130 and has sufficient structural strength to position other components of systems 120, 122. In the illustrated example, base member 140 includes a base plate 142 having a first end 144 and a second end 146. In the example configuration shown in FIGS. 2 and 3, first end 144 is shown as the bottom end of base plate 142, and second end 146 is shown as the top end of base plate 142. However, as described below, the positions of ends 144, 146 may be switched by swapping or flipping base member 140 and base plate 142 relative to support post 130. As shown in FIG. 2, any portion of base plate 142 that is not necessary for structural strength may be removed to reduce the weight of systems 120, 122, for example, by forming one or more openings 147 in base plate 142.

[0039] The base member 140 may also include a first base slide rail 148 (hereinafter referred to as the "base slide rail 148") fixedly coupled to the support column 130. The base slide rail 148 may be fixedly coupled to the support column 130 by any method now known or later developed. In the example shown in FIG. 3, the base slide rail 148 is coupled to the support column 130 by a plurality of clamps 150 that grip the support column 130. During operation, the base slide rail 148 is initially positioned relative to the support column 130 in a position that positions the processing tool 152 proximate one or more surfaces 116 of the hollow component 100 to be processed. The base member 140 also includes a slide mount 154 that slidingly couples the base plate 142 to the base slide rail 148. The slide mount 154 may include any form of structural element that can slide along the base slide rail 148, such as a block of material having a slot therein that can slide along the base slide rail 148. The slide mount 154 is coupled to the base plate 142 by any method now known or later developed, such as by integral formation, welding, fasteners, or the like.

[0040] 4 is a cross-sectional view illustrating one possible configuration of the generally rectangular mating base slide rail 148 and base slide mount 154. It will be appreciated that a wide variety of other shapes and configurations are possible for the base slide rail 148 and base slide mount 154. The base slide rail 148 and slide mount 154 may include any form of sliding lubrication or facilitating material therebetween, including, but not limited to, plastic sheets and / or oil or other lubricants. The base slide rail 148 may have any desired length depending, for example, on the length of the support posts 130 and the dimensions of the hollow component 100 to be machined.

[0041] 5 is a side view illustrating systems 120, 122 having a base slide mount 154 that slidably mounts a base plate 142 of a base member 140 in an inverted position compared to FIGS. 2-3. Thus, the slide mount 154 may selectively slidably mount the base plate 142 to the base slide rail 148 in either a first position (see FIGS. 2-3) in which the first end 144 of the base plate 142 faces the mounting end 134 of the support post 130, or a second position, as shown in FIG. 5, in which the second end 146 of the base plate 142 faces the mounting end 134 of the support post 130. The reversibility of the position of the base member 140 relative to the support post 130 allows the processing tool 152 to reach different areas of the hollow component 100, including the surface facing in opposite directions relative to the support post 130.

[0042] The systems 120, 122 also include a first actuator 158 fixedly coupled to the support column 130 at a first end 160 and coupled to the base member 140 at a second end 162. The first actuator 158 is configured to selectively slidably move the base member 140 relative to the support column 130. The first actuator 158 may include any now known or later developed linear actuator capable of slidably moving the base member along the support column 130. In certain embodiments, the first actuator 158 may include a hydraulic or pneumatic linear cylinder. In other embodiments, the first actuator 158 may include a stepper motor. In the illustrated example, the first actuator 158 may include a single double-acting linear actuator, although two or more single-acting linear actuators may alternatively be used, e.g., one for retraction and one for extension. The first end 160 of the first actuator 158 may be coupled to the support column 130 using a rod member 164. The rod member 164 may have a pivot connection 166 at one end to the first actuator 158 and may have a clamp or other mechanism 168 at the opposite end that is fixedly coupled to or grips the post 130. The first actuator 158 may be coupled to the base plate 142 of the base member 140 by another pivot connection 170.

[0043] The systems 120, 122 may also include a tool slide rail 176 coupled to the base member 140 and extending perpendicular to the support column 130. The systems 120, 122 may also include a processing tool slide mount 180 (hereinafter referred to as the "tool slide mount 180") slidingly coupled to the tool slide rail 176. The tool slide rail 176 may have any desired length depending, for example, on the (lateral) dimension of the hollow component 100 to be machined. More specifically, the tool slide rail 176 may have a length configured to position the processing tool 152 at any lateral location required for machining the desired surface(s) 116 of the hollow component 100. FIG. 4 also illustrates, for example, a cross-sectional view of one possible configuration of the mating, generally rectangular tool slide rail 176 and tool slide mount 180. It will be appreciated that a wide variety of other shapes and configurations are possible for the tool slide rail 176 and tool slide mount 180. Tool slide mount 180 may include any form of structural element that is slidable along tool slide rail 176, such as a block of material having a slot therein that is slidable along tool slide rail 176. Tool slide rail 176 and tool slide mount 180 may include any form of sliding lubricating or facilitating material therebetween, examples of which include, but are not limited to, a plastic sheet and / or oil or other lubricant.

[0044] 2 and 5, the systems 120, 122 also include a second actuator 184 coupled to the base member 140 at a first end 186 and coupled to the tool slide mount 180 at a second end 188. The second actuator 184 is configured to selectively move the tool slide mount 180 along the tool slide rails 176 to laterally move the processing tool 152 coupled to the tool slide mount 180. The second actuator 184 may include any now known or later developed linear actuator capable of slidingly moving the tool slide mount 180 and the processing tool 152 along the tool slide rails 176. In certain embodiments, the second actuator 184 may include a (single-acting) retraction linear actuator 190 and a (single-acting) extension linear actuator 192. In certain embodiments, the one or more second actuators 184 may include hydraulic or pneumatic linear cylinders. In other embodiments, the one or more second actuators 184 may include stepper motors. 5, the second actuator 184 may include a single double-acting linear actuator 194. The first end 186 and the second end 188 of the second actuator 184 may be coupled to the tool slide mount 180 and the base member 140, respectively, in any manner, such as by pivot connection, fasteners, welding, etc. If desired, an extension arm 196 may be coupled to the base plate 142 of the base member 140 to extend the connection location of the second end 188 of the second actuator 184, as shown in FIG. 2. Various extension arms 196 of different lengths may be provided to accommodate hollow components 100 of different sizes.

[0045] The processing system 120 may also include a processing tool 152 coupled to a tool slide mount 180. The processing tool 152 may include any now known or later developed tool capable of removing material from one or more surfaces 116 of the hollow component 100, such as, for example, grinding and / or polishing. In one non-limiting example, the processing tool 152 may include a material removal tool available from Creco / Dotco Tools, Inc., located in Westlake Village, California. In certain embodiments, the processing tool 152 includes a pneumatically driven tool, although other power sources, such as hydraulics or electricity, are also possible. The tool slide mount 180 may be coupled to the processing tool 152 in any now known or later developed manner, such as by integral formation, welding, fasteners, etc. In one non-limiting example, the processing tool 152 is positioned on the tool slide mount 180 at a 45° angle relative to the tool slide rail 176. However, as shown in the exploded perspective view of FIG. 6 , the tool slide mount 180 may include an adjustable mount 198 configured to selectively position the processing tool 152 at multiple angular positions relative to the tool slide rail 176, and thus the hollow component 100. The adjustable mount 198 may be disposed between the processing tool 152 and the tool slide mount 180 (as shown) and / or between the tool slide mount 180 and the tool slide rail 176. The adjustable mount 198 may include any now known or later developed method for selectively changing the angle of rotation of the two structures. In the illustrated example, pairs of angularly arranged openings 200 in each component may be aligned, and fasteners (not shown) coupled through the openings 200 may fasten the components at any of a number of angular positions. Angular adjustment of the tool slide mount 180 allows the processing tool 152 to be positioned at different angular positions relative to one or more surfaces 116 of the hollow component 100 to accommodate the positions of the different surfaces 116 to be machined. Any desired number of angular positions may be provided.

[0046] 7 is a partial cross-sectional view illustrating the systems 120, 122 in an operating position within an exemplary hollow component 100. During operation, the systems 120, 122 are positioned in a hollow region within the hollow component 100, such as within the upper chamber 104 or lower chamber 106 of the control valve casing 102. Prior to positioning, the base slide rail 148 may be coupled to the support posts 130 in a manner that allows for a desired range of movement of the processing tool 152 in a direction along the support posts 130 to process the desired one or more surfaces 116 of the hollow component 100. More specifically, the processing tool 152 can contact, reach, and / or maintain a position for processing one or more surfaces 116 within a range of movement that the first actuator 158 can move the base member 140 and processing tool 152 along the support posts 130. The base member 140 can be positioned on the post 130 in any of the positions shown in Figures 2-3 or 5 to position the processing tool 152 in an appropriate orientation, e.g., generally upward or downward relative to the desired surface(s) 116. A first actuator 158 can provide movement along the post 130 as needed. A second actuator 184 operates to move the processing tool 152 laterally relative to the surface(s) 116 of the hollow component 100. The mounting end 134 is positioned within the hollow component 100 such that the post 130 is rotatable about its longitudinal axis (see circular arrows in Figures 2, 3, 5, and 6).

[0047] With respect to rotational movement, the systems 120, 122 may be manually rotated using a handle 206 coupled to the end 132 of the support 130, for example, as shown in FIG. 7 . This rotation may selectively rotate the support 130, base member 140, and processing tool 152 relative to the hollow component 100. Alternatively, in certain embodiments, as shown in FIG. 2 , the systems 120, 122 may include a motor 210 that is fixed relative to the hollow component 100 and operatively coupled to (the end 132 of) the support 130 to selectively rotate the support 130, base member 140, and processing tool 152 relative to the hollow component 100. The motor 210 may include any now known or later developed electric, hydraulic, or pneumatic motor capable of rotating the support 130 at a desired speed or gear ratio. The motor 210 may be fixed to the hollow component 100 in any manner, including, but not limited to, fastened to a portion of the hollow component 100 or to another stationary structure adjacent to the hollow component 100. The motor 210 may be coupled to the end 132 of the strut 130 in any manner, including, but not limited to, mating gear teeth, a chain, a belt, or the like.

[0048] FIG. 8 is a perspective view illustrating a control system 220 according to an embodiment of the present disclosure. As shown in FIGS. 2 and 8 , the systems 120, 122 may further include a control system 220 for controlling at least the first and second actuators 158, 184 and the processing tool 152. The control system 220 may also control the motor 210, if present. Thus, the control system 220 may control the first and second actuators 158, 184, the motor 210, and the processing tool 152. In certain embodiments, as shown in FIG. 8 , the control system 220 may include manually operated features, such as levers, switches, or the like, to control power supply from one or more power sources, e.g., hydraulic, pneumatic, or electrical sources. In other embodiments, as shown in FIG. 2 , the control system 220 may include any now known or later developed computer numerically controlled (CNC) controller configured to control the operation of the first and second actuators 158, 184, the motor 210 (if present), and the processing tool 152. In the latter case, the first and second actuators 158, 184 may each include a stepper motor to more precisely control the positioning of these actuators. Because the operation of CNC controllers is well known, further details will not be provided, and the reader can focus on the key points of this disclosure. As shown in FIG. 2 , the systems 120, 122 may further include a digital position estimation system (DPS) 226 configured to sense the position of the machining tool 152 in three-dimensional space. The DPS 226 may include any number and any form of position sensors to position various components of the systems 120, 122, for example, relative to one another and / or a predetermined origin, and ultimately determine the location of the machining tool 152 relative to one or more surfaces 116 of the hollow component 100. Those skilled in the art will recognize that a wide variety of position sensor types are applicable in this configuration. For example, the DPS 226 may include sensors such as, but not limited to, Hall-effect sensors, potentiometers, magnetoresistive position sensors, optical position sensors, capacitive position sensors, magnetic strip sensors, and the like.The DPS 226 may interact with the control system 220, in a manner known in the art, to ascertain the location of the machining tool 152 and / or define the path of motion of the machining tool 152 in three-dimensional space. Because the interactive operation of position sensors and CNC controllers is well known, further details will not be provided and the reader can focus on the important aspects of this disclosure.

[0049] 2 and 5, systems 120, 122 may also optionally include at least one camera 230 positioned relative to support 130 to capture images (video and / or still images) of the operation of processing tool 152. Systems 120, 122 may also include a video display 232 configured to display images from one or more cameras 230, as shown in Figure 8. Feedback from one or more cameras 230 may allow control system 220 to control operation, for example, manually or automatically.

[0050] Although not shown, systems 120, 122 may include any now known or later developed harnesses and / or quick connect couplings for the various hydraulic, pneumatic, and / or electrical lines necessary to operate the systems and facilitate portability, operation, and maintenance of systems 120, 122.

[0051] Systems 120, 122 can be configured to enable the processing of any large now known or later developed hollow component 100 where it is desirable to avoid the need for internal access by a human operator. More particularly, systems 120, 122 can be sized to accommodate insertion into any size hollow component 100 by controlling, among other things, the length of posts 130 and / or the width of base member 140.

[0052] Embodiments of the present disclosure provide various technical and commercial advantages, examples of which are described herein. The systems described herein provide for remote machining of hollow regions of large hollow components, e.g., hollow components large enough for a human to fit inside at least a portion of the hollow component. The systems thereby eliminate the need for a human worker to access and perform repairs on hollow regions inside the hollow component. The systems are precise, lightweight, portable, and highly adjustable to fit hollow components of different shapes and sizes.

[0053] As used herein throughout the specification and claims, approximation may be applied to modify any quantitative expression that can be varied to a reasonable extent without resulting in a change in the basic function involved. Thus, values ​​modified by one or more terms such as "about," "approximately," and "substantially" are not limited to the exact value specified. In at least some instances, approximation may correspond to the precision of the instrument for measuring the value. Here, and throughout the specification and claims, range limitations may be combined and / or interchanged, and unless otherwise indicated by context or language, such ranges are specified and include all subranges encompassed by the range. "Approximately" or "about" applied to a particular value in a range applies to both endpoints and may indicate ±10% of the stated value or values, unless specific reliance is placed on the precision of the instrument for measuring the value.

[0054] Corresponding structures, materials, acts, and equivalents of all "means-or-step-and-function combination" elements in the following claims are intended to include any structure, material, or act for performing that function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or to limit the disclosure to the disclosed form. Many changes and modifications will be apparent to those skilled in the art without departing from the scope of the present disclosure. The embodiments were chosen and described in order to best explain the principles of the disclosure and practical applications of the technology, and to enable those skilled in the art to understand the disclosure and consider various modifications thereto, as may be suitable for the particular use intended. [Explanation of symbols]

[0055] 100 Hollow Components 102 Casing 104 Upper Chamber 106 Lower Chamber 108 Steam inlet / outlet opening 110 Steam inlet / outlet opening 112 Opening 114 Opening 116 sides 120 Processing System 122 Machining Tool Positioning System 130 Post 132 first end 134 second attachment end 134 Mounting end 136 Bush 140 Base material 142 base plate 144 first end 146 Second End 147 Opening 148 Base slide rail 150 clamp 152 Processing Tools 154 Slide Mount 158 First Actuator 160 first end 162 Second End 164 Bar members 166 Swivel connection 168 Mechanism 170 Swivel connection 176 Tool Slide Rail 180 Machining Tool Slide Mount 184 Second Actuator 186 First End 188 Second End 190 contraction linear actuator 192 Extension Linear Actuator 194 Double-acting Linear Actuator 196 Extension Arm 198 Adjustable Mount 200 openings 206 Handle 210 Motor 220 Control System 226 Digital Positioning System 230 Camera 232 Video Display

Claims

1. A processing tool positioning system (122), comprising: A support (130); a base member (140) slidably attached to the support post (130); a first actuator (158) fixedly coupled to the support post (130) at a first end (160) of the first actuator (158) and coupled to the base member (140) at a second end (162) of the first actuator (158), the first actuator (158) configured to selectively slidably move the base member (140) relative to the support post (130); a tool slide rail (176) coupled to the base member (140) and extending perpendicular to the support column (130); a machining tool slide mount (180) slidably coupled to the tool slide rail (176); a second actuator (184) coupled to the base member (140) at a first end (186) of the second actuator (184) and coupled to the machine tool slide mount (180) at a second end (188) of the second actuator (184), the second actuator (184) configured to selectively move the machine tool slide mount (180) along the tool slide rail (176); A processing tool positioning system (122) comprising:

2. 2. The processing tool positioning system (122) of claim 1, comprising: The base member (140) a base plate (142) having a first end (144) and a second end (146); a base slide rail (148) fixedly coupled to the support post (130); a slide mount (154) that slidably couples the base plate (142) to the base slide rail (148); Including, the support (130) includes a mounting end (134), and the slide mount (154) is configured to selectively and slidingly mount the base plate (142) to the base slide rail (148) in either a first position in which a first end (144) of the base plate (142) faces the mounting end (134) of the support (130), or a second position in which a second end (146) of the base plate (142) faces the mounting end (134) of the support (130).

3. 3. The processing tool positioning system (122) of claim 1 or 2, further comprising a motor (210) operatively coupled to the support (130) and specifically configured to selectively rotate the support (130).

4. 4. The processing tool positioning system (122) of claim 1, wherein the first actuator (158) includes one single double-acting linear actuator (194), and the second actuator (184) includes a retraction linear actuator (190) and an extension linear actuator (192).

5. 5. The machining tool positioning system (122) of claim 1, wherein the machining tool slide mount (180) includes an adjustable mount (198) configured to selectively position the coupled machining tool (152) at a plurality of angular positions, particularly relative to the support post (130).

6. 6. The processing tool positioning system (122) of claim 1, further comprising a control system (220) for controlling the first actuator (158) and the second actuator (184).

7. 7. The machining tool positioning system (122) of claim 6, when including the features of claim 2, wherein the control system (220) is further configured to control the motor (210).

8. 8. The processing tool positioning system (122) of claim 1, wherein the first actuator (158) and the second actuator (184) each comprise a stepper motor.

9. 9. The processing tool positioning system (122) of claim 1, further comprising: at least one camera (230) positioned relative to the support (130) to film operation of the processing tool (152); and a video display (232) configured to display images from the at least one camera (230).

10. 10. The machining tool positioning system (122) of any one of claims 1 to 9, further comprising a digital position estimation system (226) configured to sense a position of the machining tool (152) in three-dimensional space.

11. 11. The machining tool positioning system (122) of any one of claims 1 to 10, further comprising a bushing (136) configured to rotatably mount the post (130) relative to the hollow component (100).

12. 12. The machining tool positioning system (122) of any one of claims 1 to 11, wherein the support (130) is configured to be rotatably mounted to the hollow component (100).

13. 13. A machining tool positioning system (122) according to claim 11 or 12, when including the features of claim 3, wherein the motor (210) is fixed to the hollow component (100) and operatively coupled to the support (130) so as to selectively rotate the support (130) and the base member (140) relative to the hollow component (100).

14. A processing system (120) comprising: a processing tool positioning system (122) according to any one of claims 1 to 13; and a processing tool (152) coupled to the processing tool slide mount (180).

15. 15. The machining system (120) of claim 14, wherein the machining tool positioning system (122) includes the features of claim 3 and comprises a control system (220) including a computer numerically controlled (CNC) controller configured to control the operation of the first and second actuators (158, 184), the motor (210), and the machining tool (152).

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