Flange-Mounted Lifting Structure for Tensioning Tool Handling
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Solution Overview
Problem
Existing lifting and transporting devices for screw bolt connections in flange connections require cumbersome manual handling and additional support structures, making the process of pretensioning and transporting multiple connections inefficient and labor-intensive.
Innovation Solution
A lifting and transporting device that is mounted on the flanges and extends along the flange upper side to the underside, allowing for easy engagement and pretensioning of screw bolt connections from above, with a force amplification mechanism such as gas pressure cylinders or a block and tackle system to reduce manual effort, and a lever mechanism for simple actuation, minimizing space requirements and eliminating the need for external support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lifting and transporting device is mounted on external support structures, then the device has stable support, but the device requires additional space and complex installation
Solution Approach 1:
The lifting and transporting device is merged with the flange structure itself. The device utilizes the flange's own geometry (through-holes, upper side, face, and underside) as mounting locations, eliminating the need for external support structures. The frame is suspended from the flange upper side and extends along the flange face to the underside, integrating the support function into the flange assembly.
Solution Approach 2:
The flange structure serves multiple functions: it acts as both the connection element and the support structure for the lifting device. The through-holes serve dual purposes as both fastening locations and mounting points for the device. This multi-functionality reduces the need for additional components and simplifies installation.
2Device complexity
If manual handling is used for tensioning tools, then the device structure is simple, but the manual effort required is excessive
Solution Approach 1:
A gas pressure cylinder is introduced as the hoisting device to provide automated lifting capability. The gas pressure cylinder converts pneumatic energy to mechanical motion, automatically raising and lowering the holding device and tensioning tool without requiring excessive manual effort. This maintains relatively simple structure while dramatically improving ease of operation.
Solution Approach 2:
The manual mechanical lifting system is replaced with a gas pressure-based system. Instead of relying solely on manual force to lift heavy tensioning tools, the gas pressure cylinder provides the necessary lifting force, substituting pneumatic/hydraulic action for pure mechanical manual operation.
3Volume of moving object
If the lifting device extends along the flange face to the underside, then the space requirement is minimized, but the device structure becomes more complex
Solution Approach 1:
The lifting device utilizes the vertical dimension by extending from the flange upper side along the flange face to the flange underside. This vertical arrangement minimizes the horizontal space footprint in front of the flanges while accomplishing the lifting function. The frame is suspended from above and reaches down to engage with the underside, effectively using the available vertical space.
Solution Approach 2:
The device is segmented into functional sections: a frame suspended from the flange upper side, a holding device for the tensioning tool, and support bearings positioned at strategic locations. This segmentation allows the device to achieve the required reach from upper side to underside while maintaining manageable structural complexity through modular design.
4Productivity
If the tensioning tool is lifted frequently for multiple connections, then the productivity increases, but the manual effort accumulates
Solution Approach 1:
The gas pressure cylinder provides automated lifting capability that can be repeatedly activated without accumulating manual fatigue. Each lifting cycle for moving to the next screw bolt connection is powered by the gas pressure system, maintaining consistent performance throughout the assembly process and enabling high productivity without proportional increase in manual effort.
Solution Approach 2:
The hoisting device with gas pressure cylinder performs the lifting action autonomously without requiring continuous manual intervention. The system serves itself by using stored pneumatic energy to automatically raise and lower the tensioning tool, reducing the operator's physical burden while maintaining high assembly speed through rapid repeated cycles.
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
Enables quick and efficient pretensioning and transportation of screw bolt connections with reduced manual effort, allowing for easy handling of heavy tensioning tools and minimizing the need for additional support structures, thus improving the overall efficiency and ease of assembly.
Implementation Method 1
force amplification mechanism such as gas pressure cylinders
Implementation Method 2
force amplification mechanism such as gas pressure cylinders or a block and tackle system
Implementation Method 3
a lever mechanism for simple actuation
Data Source
AI summary
In a lifting and transporting device for lifting a load (13) and for transporting the same transversely to the lifting direction (8), for use in the production of a screwed flange connection (35), in order to bring a tensioning tool (13) into a tensioning position in which it is in engagement with a screw bolt connection (18) to be pretensioned, or into a transport position in which it is out of engagement with a screw bolt connection and can be transported to the next screw bolt connection, wherein the flange (36a, 36b) extends horizontally, comprising a frame (2) for picking up and for lifting a load (13), a holding device (3) for holding the load, wherein the holding device is movable relative to the frame in the lifting direction (8), and comprising a hoisting device (4) for lifting and lowering the holding device (3) with the load (13) attached thereto, wherein the frame (2) is mounted on a first and a second support bearing (5, 6) and the first support bearing (5) is designed for abutment against the flange upper side (14), the frame (2) is designed to extend from the flange upper side (14) along the flange face (15) to below the flange underside (16), the second support bearing (6) is designed for abutment against the flange upper side (14) or against the flange face (15), the holding device (3) is equipped to hold the tensioning tool (13) below the flange underside (16) with the engaging means directed upwards, and the hoisting device (4) is equipped to lift the holding device (3) with the tensioning tool (13) attached thereto from a lowered transport position into a tensioning position.