Automated High-Pressure Cleaning Unit with Interchangeable Positioning Units
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Solution Overview
Problem
High-pressure cleaning devices pose safety risks and physical burdens on operators due to the need for protective clothing and handling of high recoil forces, making them less suitable for automation and efficient cleaning of identical components.
Innovation Solution
A high-pressure cleaning device with a robot array, industrial robot, high-pressure water nozzle, and detachable positioning units with bevels and guides for precise component alignment, allowing for automated operation and remote control, reducing operator exposure and enabling efficient cleaning of identical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual high-pressure cleaning operation is used, then operator can directly control the cleaning process, but operator safety is compromised due to exposure to high-pressure water jets and recoil forces
Solution Approach 1:
An automated positioning unit with clamping means acts as an intermediary between the operator and the component, enabling remote handling and positioning of components during high-pressure cleaning. The positioning unit can be detached and repositioned without operator exposure to high-pressure zones, while still maintaining precise component positioning through automated control systems.
2Reliability
If operator wears protective clothing for safety, then operator is protected from high-pressure water jets, but physical work capability is reduced due to restricted movement and heavy burden
Solution Approach 1:
The operator is extracted from the immediate cleaning zone by implementing automated positioning units and remote handling systems. The positioning units can be manually positioned initially (without full protective gear) and then remain stationary during the automated high-pressure cleaning process, eliminating the need for operators to wear heavy protective clothing during the actual cleaning operation.
3Manufacturing precision
If high-pressure water jet is used for cleaning, then cleaning effectiveness is improved, but recoil forces increase making the process difficult to control manually
Solution Approach 1:
The positioning unit serves as a stable intermediary platform that absorbs and anchors the recoil forces generated by high-pressure water jets. By clamping the component securely to the positioning unit and using the positioning unit's weight and friction against the support surface, the system can withstand forces of several hundred newtons without requiring the operator to manually counteract the recoil during cleaning.
4Manufacturing precision
If multiple identical components are cleaned sequentially, then comprehensive cleaning coverage is achieved, but cleaning time increases due to repeated positioning and setup
Solution Approach 1:
Components are pre-positioned on positioning units outside the cleaning zone, and multiple positioning units are prepared in advance with different components. The automated system can then sequentially move between pre-prepared positioning units without requiring setup or repositioning time, as all positioning units are already configured with components ready for cleaning.
Solution Approach 2:
The positioning units are designed as universal, interchangeable modules that can hold different components in the same standardized position. This allows the automated cleaning system to use a single cleaning program for all components across multiple positioning units, eliminating the need for reprogramming or adjustment when switching between different components or positioning units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances safety by minimizing operator exposure and physical strain, facilitates precise and efficient cleaning of identical components through automated operation, and allows for remote control of the cleaning process, reducing the risk of injuries and improving productivity.
Implementation Method 1
In high-pressure cleaning, water jets are used, which can have a very high penetrating power due to the high pressure
Implementation Method 2
when a positioning unit is in the installed state on the component field, the guides bear against the fitting bevels
Data Source
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AI summary
The high-pressure cleaning device for contaminated components has a) a base frame (20) comprising a robot platform (22) and at least one component platform (24), b) an industrial robot arranged on the robot platform (22), which has a working area extending substantially over the at least one component platform (24, 25) and which has a robot hand (32), c) a high-pressure water nozzle (36) connected to a high-pressure supply via a flexible high-pressure hose (38) and arranged on the robot hand (32), d) at least one positioning unit (46) detachably connected to the component platform (24, 25) and comprising clamping means (50-54) for the detachable fastening of a component (34). The component platform (24, 25) has chamfers (44). The positioning unit (46) has guides (48) adapted to the chamfers (44).The locating chamfers (44), together with the guides (48), position the positioning unit (46) on the component area (24, 25). When a positioning unit (46) is installed on the component area (24), the guides (48) rest against the locating chamfers (44).