Insulating Boom Pinned Connection for Repairable Powerline Access
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Solution Overview
Problem
Aerial devices used for working on energized power lines face challenges with permanent connections between insulating and non-insulating boom sections, which are difficult to repair and require adhesive processes with long cure times, and have limited access for hydraulics and sensors, necessitating improvements in articulation and modular components.
Innovation Solution
The use of pinned connections and articulating joints between insulating and non-insulating boom sections, along with modular sleds for housing hydraulic systems, allows for load transfer without adhesives, enabling easier assembly, repair, and increased mobility, while providing improved access to sensitive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive connections are used to join insulating and non-insulating boom sections, then a permanent connection is created, but the assembly becomes difficult to repair and requires long cure times
Solution Approach 1:
The connecting assembly is divided into separate modular components: structural members, collars, and pins. This segmentation allows individual components to be replaced independently without replacing the entire boom assembly, directly addressing the repairability issue while maintaining strong connections through properly designed joint interfaces
Solution Approach 2:
The patent replaces the chemical adhesive bonding system with a mechanical pinned connection system. The mechanical connection using pins and collars eliminates the need for adhesive cure times and allows for easy disassembly and repair, while still providing the required connection strength through engineered mechanical interfaces
2Strength
If adhesive connections are used to join boom sections, then a permanent connection is created, but manufacturing and assembling time increases due to long cure and preparation times
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical pinned connection system. The mechanical connection using pins and collars eliminates the need for adhesive cure times and allows for easy disassembly and repair, while still providing the required connection strength through engineered mechanical interfaces
Solution Approach 2:
The collars are pre-positioned within the insulating section and the structural members are prepared with pin receptacles before final assembly. This preliminary preparation allows the actual connection to be made quickly by simply inserting the pins, significantly reducing assembly time while ensuring proper alignment and connection strength
3Adaptability or versatility
If hydraulics and sensors are housed in a distalmost stage with limited access, then component integration is achieved, but access for maintenance becomes difficult
Solution Approach 1:
The lower boom section is segmented into a modular sled that houses the hydraulics and sensors. This sled can be independently removed from the boom assembly, providing excellent access to all components for maintenance while maintaining integrated functionality when assembled. The segmentation allows the hydraulic/sensor package to be serviced without disassembling the entire boom structure
Solution Approach 2:
The hydraulic and sensor components are extracted from the distalmost stage and relocated to a separate modular sled. This extraction provides easy access to these components for maintenance and repair, while the sled design ensures all necessary connections and integrations are maintained when the sled is mounted on the boom section
Data Source
AI summary
An aerial device for operating on energized powerlines is disclosed. The aerial device may have a boom assembly with a lower, electrically non-insulating boom section coupled to an upper, electrically insulating boom section. The lower and upper boom sections may be coupled by a pinned connection that utilizes structural collars and structural pins to handle loads applied to the upper boom section. The upper boom section may articulate relative to the lower boom section using a 4-bar mechanism employing a split pivot pin that enables a greater range of motion for the articulation. A modular sled that can be coupled to various boom assemblies is also disclosed.