Rotatable Tool Post Positioning for Hollow Interior Machining
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Solution Overview
Problem
Large industrial components, particularly hollow components like steam turbine control valve casings, experience cracking after extended use, necessitating machining repairs that require human operators to enter cramped and uncomfortable positions within the hollow areas.
Innovation Solution
A machining tool positioning system that includes a rotatable post, sliding base member, actuators, and a machining tool slide mount, allowing for remote operation and precise positioning of machining tools within the hollow component, eliminating the need for human access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a human operator enters the hollow area within the chambers to machine surfaces, then the machining operation can be performed, but the operator experiences uncomfortable and cramped positions
Solution Approach 1:
A robotic arm system acts as an intermediary between the operator and the machining task. The robotic arm includes a base plate with rollers that move along rails, a multi-jointed arm with actuators, and a machining tool at the end effector. This intermediary device performs the machining operation inside the hollow chamber without requiring human entry, thereby resolving the contradiction between operator comfort and system complexity.
2Adaptability or versatility
If the machining tool is positioned manually by human operator, then the operation can be performed, but access to difficult to access locations is limited
Solution Approach 1:
The robotic arm employs multiple joints with actuators that provide dynamic positioning capability. The arm can rotate and position the machining tool at various angles and locations within the hollow chamber. This dynamic positioning system overcomes the limitations of manual access to difficult locations while maintaining adaptability to different machining requirements.
3Reliability
If a robotic system is introduced to machine hollow components, then human operators do not need to enter cramped areas, but the device complexity increases
Solution Approach 1:
The robotic system is segmented into distinct functional modules: a base plate with rollers for linear movement, a multi-jointed arm with individual actuators for each joint, and a machining tool at the end effector. This segmentation allows each component to be optimized independently and simplifies the overall control system, thereby improving operational safety while managing device complexity through modular design.
Data Source
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AI summary
A machining tool positioning system includes a post configured to rotatably mount relative to a hollow component to be machined. A base member slidingly mounts relative to the post. A first actuator is configured to selectively slidingly move the base member relative to the post. A tool slide rail is coupled to the base member and extends perpendicular to the post. A machining tool slide mount slidingly couples to the tool slide rail and is configured to position a machining tool relative to the rail. A second actuator is coupled at a first end to the base member and coupled at a second end to the machining tool slide mount is configured to selectively move the machining tool slide mount along the rail. A motor may optionally turn the post to rotate the position of the base member and machining tool.