Continuous Nut-Plane Drive for Flange Nut Tightening Robots
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Solution Overview
Problem
Existing bolt tightening solutions for wind turbine tower construction are labor-intensive and costly due to the use of electromagnets for propulsion, which increase power requirements and complexity.
Innovation Solution
A tightening device with a continuous drive disposed on the nut plane of pre-screwed nuts, utilizing the top surfaces of the nuts as a drive surface for propulsion, eliminating the need for additional mechanisms and reducing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromagnets are used to press the belt drive against the side wall for propulsion, then the robot achieves reliable propulsion along the flange connection, but the power requirements and device complexity increase significantly
Solution Approach 1:
The invention extracts and eliminates the electromagnets from the propulsion system. Instead of using electromagnets to press the belt drive against the side wall, the patent uses a passive belt drive that relies on friction between the belt and the flange connection surface, thereby removing the complex electromagnetic components while maintaining propulsion functionality
Solution Approach 2:
The belt drive system is designed to propel itself along the flange connection through friction-based interaction with the surface. The system uses the existing flange connection as both the work surface and the propulsion surface, eliminating the need for additional active propulsion mechanisms like electromagnets
2Reliability
If electromagnets are used to press the belt drive against the side wall for propulsion, then the robot achieves reliable propulsion along the flange connection, but the operational costs and manufacturing costs increase
Solution Approach 1:
The invention replaces expensive electromagnets with a simple, inexpensive belt drive system. The belt and pulley components are much cheaper to manufacture and install compared to electromagnetic propulsion systems, significantly reducing both initial manufacturing costs and operational expenses
Solution Approach 2:
By removing the electromagnet components entirely, the invention eliminates the associated manufacturing complexity, material costs, and installation requirements, resulting in a more cost-effective solution that uses only essential mechanical components
3Device complexity
If manual torque wrenches are used for bolt tightening, then the construction process is simple and equipment cost is low, but the labor intensity and construction time increase significantly
Solution Approach 1:
The tightening device is designed to move and position itself automatically along the flange connection using the passive belt drive system. The device propels itself from one bolt location to the next without requiring manual repositioning, thereby automating the tightening process while keeping the overall system relatively simple
Solution Approach 2:
The same flange connection surface that serves as the work surface for bolt tightening also serves as the propulsion surface for the belt drive. This multi-functional use of the flange connection eliminates the need for separate propulsion mechanisms, maintaining equipment simplicity while enabling automated operation
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 provides a reliable, robust, and cost-effective means of automatically tightening bolts in wind turbine towers, reducing labor intensity and operational costs while maintaining efficient propulsion along the flange connection.
Implementation Method 1
the continuous drive interacts with the nuts in a way, that the continuous drive can also grip the edges of the nuts and can use these edges to provide grip
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Tightening device (1) for tightening a series of nuts (2) pre-screwed on bolts (3), which bolts (3) are arranged in a linear or in a curved flange connection (4), wherein each nut (2) comprises a top surface (5) located at one end of the nut (2), wherein the top surfaces (5) are arranged in a nut plane (6) of the flange connection (4), and wherein the tightening device (1) comprises a propulsion unit (7) for moving the tightening device (1) along the flange connection (4), wherein the propulsion unit (7) comprises a continuous drive (8), wherein in an operating state of the tightening device (1), the continuous drive (8) is disposed essentially on the nut plane (6) on one or more top surfaces (5) of one or more of the nuts (2).