Heavy-Load Alignment Jig With Independent Multi-Axis Actuation
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Solution Overview
Problem
Existing alignment methods for large and heavy units in heavy engineering applications are time-consuming, hazardous, and often result in inadequate alignment, requiring ad-hoc jig arrangements that lack precision and flexibility.
Innovation Solution
An alignment system comprising a base unit and support unit with independent actuation systems, allowing for precise orientation and movement of loads using actuators and a track system that can be installed on any substrate without modification, enabling safe and efficient alignment of heavy units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ad-hoc jig arrangements are used for alignment, then flexibility in installation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The alignment system is divided into modular components: a base unit with actuation system, a support unit with independent actuation, and a track system. This segmentation allows each module to be independently manufactured and assembled, maintaining installation flexibility while achieving precise alignment through coordinated operation of the segments.
Solution Approach 2:
The base unit and support unit are designed as universal modules that can be used for aligning different types of heavy units in various applications. The actuation systems provide multi-functional capability for positioning, orienting, and securing loads, thereby achieving both flexibility and precision through standardized yet adaptable components.
2Device complexity
If manual jacking and hydraulic pulling are used for alignment, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The system replaces manual mechanical operations (jacking and hydraulic pulling) with an automated actuation system comprising actuators, control units, and sensors. This substitution maintains relative structural simplicity while dramatically increasing alignment speed and productivity through automated control.
3Ease of operation
If conventional crane arrangements are used for positioning, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The alignment system incorporates sensors and control units that provide real-time feedback on the position and orientation of the support unit relative to the base unit. This feedback loop enables automated adjustment and precise control, achieving high orientation accuracy while maintaining ease of operation through automated control.
Solution Approach 2:
The system uses dynamic actuation systems that can adjust positioning and orientation in real-time during the alignment process. The actuators provide controlled movement along multiple axes, enabling precise orientation adjustment while maintaining operational ease through automated control sequences.
Data Source
AI summary
An alignment jig (10) configured to support and orient a load (500). The alignment jig (10) may form part of an alignment system (300). The alignment jig (10) comprises a first base unit (100) configured to carry a first support unit (200), the first support unit (200) being configured to support the load (500) and to space the first base unit (100) apart from the load (500). The first support unit (200) is moveable relative to the first base unit (100). The first base unit (100) comprises a first base unit actuation system (110) operable to act on the first support unit (200) along a first base unit operational axis X1. The first support unit (200) comprises a first support unit actuation system (210) operable to act on the load (500) along a first support unit operational axis Y1.