Heated Robotic Clamp for Precise Annular Component Installation
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Solution Overview
Problem
Manual installation of annular components, such as bushings, in aircraft systems and industrial machinery is hazardous, prone to errors, and inefficient due to operator fatigue and variability, leading to safety concerns and increased labor costs.
Innovation Solution
A robotic system with an engagement clamp and heating element, controlled by a processor, automates the installation process by engaging, heating, and positioning the annular component relative to a work-piece, ensuring accurate engagement upon cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual heating and handling of pre-heated bushing is performed, then the bushing can be installed about the torque tube, but operator safety is compromised due to high temperature exposure
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system that uses a gripper to hold and position the pre-heated bushing. The robotic arm precisely positions the bushing while a heating element maintains its temperature, eliminating direct operator exposure to high temperatures and improving safety.
Solution Approach 2:
The robotic gripper acts as an intermediary between the operator and the hot bushing. The system includes a heating element that serves as a mediator to maintain the bushing temperature during the automated installation process, preventing temperature loss without requiring manual intervention.
2Ease of operation
If operators manually position work-pieces at awkward angles, then bushing installation can be performed, but workmanship quality deteriorates due to inherent errors and defects
Solution Approach 1:
The patent replaces manual positioning operations with a robotic arm that can precisely position the work-piece at required angles. The automated system eliminates human error and fatigue-related defects, ensuring consistent workmanship quality while handling awkward angles and difficult-to-reach positions.
Solution Approach 2:
The system incorporates sensors and control systems that provide feedback to ensure precise positioning of the bushing relative to the torque tube. This feedback mechanism maintains accurate alignment and position throughout the installation process, preventing positioning errors.
3Productivity
If manual heating and positioning steps are performed, then bushing installation can be completed, but productivity decreases due to installation time and labor requirements
Solution Approach 1:
The patent combines multiple operations (heating, positioning, and installation) into a single automated robotic system. The heating element, gripper, and robotic arm work together in coordination to perform all steps continuously without manual intervention, significantly reducing total installation time and improving productivity.
Solution Approach 2:
The system maintains continuous heating of the bushing throughout the installation process using an integrated heating element. The robotic arm continuously holds and positions the bushing without interruption, eliminating idle time and ensuring the bushing remains at the required temperature until installation is complete.
4Adaptability or versatility
If different operators perform bushing installations, then various installations can be completed, but consistency deteriorates due to variability in operator techniques
Solution Approach 1:
The patent replaces variable human operators with a consistent robotic system that executes the same programmed operations for every installation. The automated system eliminates operator-to-operator variability, ensuring uniform quality and consistency across all bushing installations while maintaining the ability to adapt to different work-pieces through programmable control.
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 reduces installation time, improves safety, minimizes labor, and enhances workmanship consistency by automating the handling and positioning of high-temperature annular components, reducing operator fatigue and variability.
Implementation Method 1
pre-heating the bushing and then manually inserting the bushing about the torque tube
Implementation Method 2
the annular component engages the work-piece upon cooling
Data Source
AI summary
A component installation system includes an engagement clamp having a circular shape coupled to a robotic arm, being configured to engage an annular component. The component installation system further includes an actuator coupled to the engagement clamp and operable to cause the engagement clamp to engage and disengage the annular component, and a heating element coupled to the engagement clamp and arranged to heat the annular component engaged within the engagement clamp. The component installation system further includes a controller in communication with the robotic arm, the actuator and the heating element.