Flange-Tightening Robot Rail Drive for Confined Spaces
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Solution Overview
Problem
Existing robots designed to tighten bolt connections in curved flange connections are limited by their requirement for space and cannot operate in confined areas, such as close to walls or in spaces with obstacles, making them inefficient for applications like wind turbines and oil platforms.
Innovation Solution
A robot system with a support platform that can move along a series of nuts pre-screwed on bolts in curved flange connections, equipped with a star-shaped radial plate and guiding rails, allowing it to navigate close to walls and obstacles, and featuring tools like a bolt stretch tool and torque wrench for fully automatic tightening with predefined preload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a robot with wheels is used to move along the flange connection, then the robot can tighten bolts with predefined torque, but the robot requires a certain amount of space and cannot operate close to walls or in confined spaces
Solution Approach 1:
The robot is divided into separate functional modules: a mobile base unit with drive mechanism and a detachable tool unit for bolt tightening. This segmentation allows the compact base to navigate confined spaces while the tool unit performs the tightening function, reducing the overall space requirement compared to integrated wheel-based designs.
Solution Approach 2:
The drive mechanism transitions from wheel-based rolling motion (requiring lateral space) to a linear propulsion method that moves along the flange connection in a straight line. This dimensional change in the drive approach allows operation in narrower spaces where wheels cannot maneuver.
2Adaptability or versatility
If manual procedures are used for nut application and tightening, then flexibility in operation is maintained, but the process is time-consuming, expensive, and prone to human error
Solution Approach 1:
The robot system performs the tightening operation autonomously without requiring human intervention for each bolt. The automated control system manages the entire tightening sequence, applying predefined torque values consistently, which eliminates human error while maintaining operational flexibility through programmable parameters.
Solution Approach 2:
The system incorporates sensors and control mechanisms that provide feedback on tightening progress and torque application. This closed-loop control ensures precise torque delivery for each bolt, maintaining quality standards while automating the process to improve productivity and reduce variability compared to manual operations.
3Adaptability or versatility
If manual tightening procedures are used, then human judgment can be applied, but the process is very risky and often faulty
Solution Approach 1:
The system uses programmable parameters to define precise torque values and tightening sequences for different bolt locations. By converting human judgment into standardized numerical parameters, the system maintains the benefits of expert knowledge while eliminating human error, ensuring consistent and reliable tightening quality across all operations.
Data Source
Figure 1~2
Figure 3A~4
Figure 5A~6
AI summary
Robot (1) to move a support platform (6) along a series of nuts (2) pre-screwed on bolts (3) arranged in a linear or in particular curved flange connection (4). The bolts (3) project from the nuts (2) pre-screwed in substantially a nut plane (13) by a projection length (15). The robot (1) comprises a drive to move the robot (1) along the curved flange connection (4). The drive comprises at least one drive element (12) and holding means (11) both connected to the support platform (6), wherein the holding means (11) comprise at least one pair of guiding rails (16, 17) connected to the support platform (6) in a distance from each other of more than the diameter (D) of the bolts (3) and less than the width across flat (AF) of the nuts (2) and projecting more than the projection length (15) from the support platform (6).