Flanged Coupling Assembly with Flexible Pulling Link Alignment
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Solution Overview
Problem
Existing flange alignment and assembly systems face challenges in aligning misaligned flanges, particularly in underwater or remote operations, due to variable 3D geometry and mechanical stresses, which can lead to safety risks and equipment damage.
Innovation Solution
A flexible elongate pulling link system with flange attachments and a puller device that tension the pulling link to apply aligning leverage and torque, allowing for three-dimensional flexibility to accommodate misalignment and facilitate hydraulic pressure-assisted assembly, enabling safe and quick alignment and coupling of flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ropes or wires are used to achieve approximate alignment of separated flanges, then alignment capability is improved, but safety risk increases due to stored elastic energy and potential sudden spring-back release
Solution Approach 1:
The patent introduces a controlled intervention system with gradually adjustable tensioning as an intermediary between the misaligned flanges. This system allows precise control over the alignment process, releasing elastic energy in a controlled manner rather than allowing sudden spring-back, thereby maintaining alignment capability while eliminating safety risks associated with uncontrolled elastic energy storage in ropes or wires
Solution Approach 2:
The patent replaces the passive mechanical system of ropes or wires with an active controlled intervention system that can precisely regulate tension application. This substitution enables controlled energy release and eliminates the hazardous sudden spring-back effect while maintaining the alignment function
2Manufacturing precision
If jacking systems are used to push flange hubs together and align mating faces, then alignment precision is improved, but device complexity and bulk increase
Solution Approach 1:
The patent segments the alignment function into multiple independently controllable tensioning points around the flange perimeter. Each tensioning point can be adjusted separately, allowing precise control of the alignment process without requiring a complex integrated jacking system, thereby achieving high alignment precision with reduced overall system complexity
Solution Approach 2:
The tensioning system is designed to perform multiple functions: it can align flanges in different positions, accommodate various misalignment scenarios, and work with different flange configurations. This multi-functionality eliminates the need for separate specialized jacking systems for different alignment tasks, reducing device complexity while maintaining alignment precision
3Device complexity
If flanges are aligned and pulled together manually or with simple tools, then equipment simplicity is maintained, but assembly time increases and productivity decreases
Solution Approach 1:
The patent employs hydraulic or pneumatic tensioning devices that can rapidly apply and release controlled forces to align and assemble flanges. These powered systems dramatically reduce assembly time compared to manual methods while maintaining relative equipment simplicity through the use of standard hydraulic/pneumatic components rather than complex custom mechanisms
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 system ensures safer and faster flange alignment and assembly, reducing the risk of personnel injury and equipment damage, while being adaptable to various flange sizes and configurations, and compatible with hydraulic systems for efficient operation.
Implementation Method 1
a flexible elongate pulling link extending between the flange attachments of the or each pair, the pulling link being engaged by, and movable relative to, the puller device to act in tension between those flange attachments
Implementation Method 2
tensioning a flexible elongate pulling link between the opposed pair of flange attachments while those flange attachments hold the pulling link outboard of the flange. This enables tension in, and consequent straightening of, the pulling link to apply aligning leverage and torque to the flanges
Implementation Method 3
The invention aims to improve the assembly of flanged couplings in these circumstances and to simplify flange-to-flange mating while applying hydraulic pressure to bring the flanges together
Data Source
AI summary
A pulling and alignment system for flanged components has pairs of flange attachments fixed to respective flanges of components that are to be pulled together and aligned for coupling. A puller device is supported by a flange attachment of each pair. A flexible elongate pulling link extends between the flange attachments of the pair and is engaged by, and movable relative to, the puller device to act in tension between those flange attachments. Each flange attachment is a flange extension that comprises an arm cantilevered from a mounting to extend beyond the flange and to hold the pulling link outboard of the flange. The pulling link is an articulated rod having a longitudinal series of rigid elements, each of those elements being pivotably coupled to at least one other of those elements.