Turntable Bogie Drive Replacement Using Pivoting Swap Cartridge
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Solution Overview
Problem
Current methods for replacing a non-working drive assembly in a turntable load station are inefficient and pose safety risks due to manual handling of heavy components, leading to prolonged downtime and ergonomic hazards.
Innovation Solution
A system and method utilizing a translating cartridge that moves along a swap rail to pivot and decouple the drive assembly from the bogie, allowing for safe and quick removal and installation of a replacement drive assembly, with automated options to minimize operator exposure and reduce downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling methods are used to replace drive assemblies, then operators can perform the replacement, but the process is time-consuming and poses safety risks due to heavy components
Solution Approach 1:
A robotic manipulator system acts as an intermediary between the operator and the heavy drive assembly components. The manipulator with grippers physically handles the drive assembly, motor, and gearbox, transferring them between positions without direct operator contact. This eliminates safety risks from manual handling while maintaining operational efficiency.
Solution Approach 2:
The patent replaces manual mechanical handling with an automated robotic manipulator system. The robotic system uses sensors, controllers, and automated grippers to perform the physical tasks of removing and installing drive assemblies, substituting human operators for automated mechanical systems that can handle heavy components safely and efficiently.
2Ease of manufacture
If manual handling of heavy drive assembly components is performed, then replacement can be done, but ergonomic hazards occur to operators
Solution Approach 1:
The robotic manipulator system performs the replacement task autonomously without requiring operator intervention in the physical handling of heavy components. The system uses automated sensors to detect component positions, calculates optimal paths, and executes the replacement sequence independently, making the system self-sufficient for the hazardous manual tasks.
Solution Approach 2:
The robotic manipulator serves as an intermediary that takes over the ergonomic-hazardous tasks of lifting, moving, and positioning heavy drive assembly components. This protects operators from exposure to harmful factors while maintaining the ability to perform replacements.
3Productivity
If automated robotic manipulator system is used, then safety and speed are improved, but device complexity increases
Solution Approach 1:
The robotic manipulator system is designed with multi-functionality to justify its complexity. It can handle multiple types of components (drive assembly, motor, gearbox), perform various operations (grasping, moving, positioning, installing), and adapt to different replacement scenarios. This universal capability maximizes productivity gains while consolidating functions into a single integrated system.
Solution Approach 2:
The system incorporates sensors that provide real-time feedback on component positions, manipulator status, and environmental conditions. This feedback loop enables the controller to make real-time adjustments, ensuring safe and efficient operation despite the increased system complexity. The feedback mechanism allows the complex system to operate reliably and adaptively.
Data Source
AI summary
Aspects of the disclosure relate to methods, apparatus, and systems for replacing a drive assembly of a turntable load station. A system includes a structural pier, a track formed on a top surface of the structural pier, a turntable, a bogie assembly detachably coupled to an underside of the turntable, the bogie assembly including a wheeled drive assembly, a swap rail mounted to a radial side surface of the structural pier, and a translating cartridge movably mounted to the swap rail in a serviceable orientation. The translating cartridge is configured to move along the radial side surface of the structural pier via the swap rail while in the serviceable orientation to an unloading position underneath the bogie assembly, pivot from the serviceable orientation to an upright functional orientation to couple with the wheeled drive assembly, and decouple the wheeled drive assembly from the bogie assembly.