Hydraulic Alignment Tool for Precise Heavy Machinery Positioning
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Solution Overview
Problem
The existing methods for aligning large machinery, such as gas turbines and generators, are time-consuming and heavily dependent on the operator's skill, leading to inconsistent results and safety risks due to manual operation of jacking screws.
Innovation Solution
A system comprising a bottom plate, top plate, low-friction intermediate element, and hydraulic or electro-mechanical actuators controlled by a remote control unit, allowing precise and controlled movement of the top plate relative to the bottom plate, reducing manual intervention and enhancing safety and alignment quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation of jacking screws is used for aligning machinery, then the alignment process can be performed with simple tools, but the alignment time is excessive and the quality depends heavily on operator skill
Solution Approach 1:
The patent replaces manual mechanical operation of jacking screws with hydraulic actuators that are controlled by a control unit. This substitution eliminates the need for manual turning of screws and provides automated, precise control over the alignment process, thereby reducing alignment time while maintaining ease of operation through remote control.
Solution Approach 2:
The patent employs hydraulic actuators to replace manual mechanical adjustment mechanisms. The hydraulic system provides controlled, precise movement of the top plate relative to the bottom plate, enabling fast and accurate alignment without manual intervention, thus resolving the contradiction between operational simplicity and time consumption.
2Device complexity
If manual operation of jacking screws is used, then the tool structure remains simple, but the alignment quality is inconsistent and safety risks increase
Solution Approach 1:
The patent replaces manual mechanical adjustment with hydraulic actuators controlled by a control unit. This substitution ensures consistent, repeatable alignment quality by eliminating human variability in manual screw operation, while the added hydraulic and control systems manage the increase in device complexity through integrated automation.
Solution Approach 2:
The patent implements a control unit that manages the hydraulic actuators, providing automated control and potential feedback mechanisms. This ensures consistent alignment quality by systematically controlling the adjustment process rather than relying on manual operator skill, thereby improving reliability while the integrated control system manages the complexity increase.
3Device complexity
If manual operation of jacking screws is used, then the tool requires fewer components, but safety risks increase due to manual intervention near heavy machinery
Solution Approach 1:
The patent replaces manual mechanical operation with hydraulic actuators controlled remotely by a control unit. This substitution eliminates the need for operators to physically handle jacking screws near heavy machinery, thereby removing the safety hazard of manual intervention while the integrated hydraulic and control systems manage the increased component count.
Solution Approach 2:
The patent introduces hydraulic actuators as intermediaries between the control unit and the machinery alignment process. This intermediary system allows remote control of the alignment process, eliminating direct human contact with moving parts and heavy equipment, thus resolving the safety issue while the intermediary components manage the complexity increase.
4Productivity
If hydraulic or electro-mechanical actuators are used to move the top plate, then alignment precision and speed improve, but the device complexity increases
Solution Approach 1:
The patent employs hydraulic actuators to achieve fast, precise movement of the top plate. The hydraulic system provides controlled, high-speed adjustment capability that dramatically improves alignment productivity, while the integrated control unit manages the complexity of the hydraulic components through automated operation.
Solution Approach 2:
The patent replaces slow manual mechanical adjustment with hydraulic or electro-mechanical actuators. This substitution provides rapid, precise control over top plate movement, improving alignment speed and productivity, while the automated control systems manage the increased device complexity through integrated operation.
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
Significantly reduces alignment time and improves precision, safety, and service life by enabling predictable and controlled movement, independent of operator skill, while maintaining alignment in multiple directions.
Implementation Method 1
a low friction intermediate element between the bottom plate and the top plate
Implementation Method 2
at least one hydraulic actuator or electro-mechanic actuator arranged between the bottom plate and the top plate capable of moving the top plate relative to the bottom plate
Implementation Method 3
at least one hydraulic actuator or electro-mechanic actuator arranged between the bottom plate and the top plate capable of moving the top plate relative to the bottom plate
Data Source
AI summary
Embodiments of the disclosure provide a tool and method for alignment adjustment of machinery. The tool may include a bottom plate, a top plate oriented in parallel planes, a low friction intermediate element between bottom plate and top plate, and a hydraulic actuator or electro-mechanic actuator arranged between the bottom plate and the top plate and capable of moving the top plate relative to the bottom plate.