Baffle Bolt Repair Platform for Faster Reactor Vessel Replacement
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Solution Overview
Problem
The existing methods for repairing baffle bolts in nuclear reactor vessels are inefficient, with current tools capable of removing only about eight bolts per day, leading to prolonged maintenance outages when many bolts need replacement.
Innovation Solution
A bolt repair platform with a frame and motor-driven rotary driver that allows for simultaneous engagement and removal of multiple baffle bolts, featuring a tool module with a rotatable driver and actuator for precise positioning and high-force engagement, enabling faster and more efficient bolt replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single tool on a mast is used to replace baffle bolts one at a time, then the device complexity is low, but the productivity is only about eight bolts per day
Solution Approach 1:
The patent combines multiple bolt replacement operations into a single integrated platform. The modular platform includes multiple tools that can work on multiple bolts simultaneously, merging what were previously separate single-bolt operations into a coordinated multi-bolt system that achieves 40-50 bolts per day replacement rate.
Solution Approach 2:
The system employs dynamic positioning mechanisms including motorized actuators and programmable logic controllers that enable the platform to adaptively move between different bolt locations. This dynamic capability allows the system to optimize its workflow and handle varying bolt configurations efficiently.
2Loss of time
If traditional single-bolt replacement tools are used, then the ease of operation is maintained, but the loss of time due to prolonged maintenance outages increases
Solution Approach 1:
The system performs preliminary positioning and preparation actions through programmable automation. The PLC-controlled platform pre-positiones multiple tools at optimal locations before bolt removal begins, and coordinates the sequence of operations in advance, eliminating idle time and ensuring continuous productive work throughout the maintenance outage.
3Speed
If a simple mast tool is used, then the device complexity is low, but the speed of bolt replacement is limited to eight per day
Solution Approach 1:
The system segments the bolt replacement task into multiple independent but coordinated operations. The modular platform divides the work among multiple specialized tools, each handling specific bolts or specific steps (removal, installation, tightening), allowing parallel execution and significantly increasing overall speed to 40-50 bolts per day.
Solution Approach 2:
The patent replaces manual mechanical operations with automated motorized systems. Electric motors and actuators control tool positioning, bolt engagement, and tightening operations, substituting human-operated mechanical systems with automated electromechanical systems that operate faster and more consistently.
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 system significantly increases the rate of baffle bolt replacement, potentially up to forty to fifty bolts per day, reducing the duration of maintenance outages and improving operational efficiency.
Implementation Method 1
a motor-driven rotary driver movably mounted on the frame. The rotary driver defines a distal end thereof that is configured to retain the second end of the tool so that, when actuated, the rotary driver rotationally drives the tool
Data Source
AI summary
A bolt repair platform includes a frame and a tool module. The tool module includes a tool having a first end configured to rotationally engage a bolt. The tool module also includes an actuator disposed between the tool and the frame so that actuation of the actuator moves the tool with respect to the frame. The frame is removably disposed on the structure, and the tool is movable with respect to the frame, so that, at each of a plurality of positions, the second end of the tool is capable of engagement with a respective bolt disposed in an internal support structure of a nuclear reactor vessel.