Inverted Robotic Arm Mounting for Stable Electrical Bypass Positioning

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Solution Overview

Problem

Existing robotic arms, such as LineMaster™, cannot be inverted to position insulators downwardly for efficiently bypassing electrical components like switches due to limited travel range, requiring cranes that risk beam rotation and stabilization issues.

Innovation Solution

A hinge coupler and boom adapter arm system is used to mount a robotic arm in an inverted position, allowing it to suspend electrical bypasses over energized components, with a pivot linkage and actuator for selective orientation, enabling downwardly extending insulators to securely position bus bars and cables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a traditional robotic arm is used with limited range of travel, then the structure remains simple, but the robotic arm cannot be inverted to position insulators downwardly for efficient bypassing

Engineering Contradiction:

Improveinversion capabilityVSAvoidstructure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The robotic arm system is divided into separate functional segments: a traditional robotic arm for conductor manipulation and a separate boom adaptor arm with hinge coupler for positioning and inversion. This segmentation allows the positioning function to be inverted while keeping the robotic arm structure relatively simple.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A boom adaptor arm serves as an intermediary component between the support structure and the robotic arm. This intermediary element provides the inversion capability through its hinge coupler mechanism without requiring modification to the robotic arm itself, thus adding versatility while controlling complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a crane is used to lower bus bars into position, then the bypass can be positioned, but the beam rotates causing instability and requiring multiple cranes and personnel

Engineering Contradiction:

ImprovestabilizationVSAvoidnumber of cranes and personnel

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The unstable cable-suspended beam mechanism of traditional cranes is replaced with a rigid boom adaptor arm system that is mechanically coupled to the support structure. This substitution eliminates beam rotation and instability while reducing the need for multiple cranes and personnel.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of suspending the beam from below as in traditional crane operations, the boom adaptor arm extends upward from the support structure to position the robotic arm and insulators from above, enabling inverted positioning while maintaining stability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If the robotic arm is inverted using the boom adaptor arm, then working clearance and positioning precision are improved, but the device complexity increases

Engineering Contradiction:

Improvepositioning precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The boom adaptor arm incorporates a hinge coupler that enables dynamic adjustment and inversion of the robotic arm position. This dynamic capability allows precise positioning of insulators downwardly while the modular design keeps the added complexity manageable.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system adds a rotational dimension through the hinge coupler mechanism, allowing the robotic arm to be inverted and positioned in previously inaccessible orientations. This dimensional addition improves positioning precision without requiring complete redesign of the robotic arm.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If multiple bucket trucks are used for stabilization, then the beam can be stabilized, but the number of personnel and equipment increases

Engineering Contradiction:

ImprovestabilizationVSAvoidnumber of equipment

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stabilization function is extracted from the crane system and integrated directly into the boom adaptor arm structure. By taking out the stabilization requirement from the external crane support and building it into the mounting structure itself, the system achieves reliability without requiring multiple additional equipment pieces.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12614896B2Mounting a robotic arm in an inverted position to suspend an electrical bypass

Publication Date: 2026.04.28 QUANTA ASSOCIATES LP

AI summary

A method and apparatus to invert a robotic arm, includes an angling adaptor and swing arm. The angling adaptor includes a truck or crane boom head adaptor and a hinge coupler. The swing arm extends downwardly from the angling adaptor and may include a boom adaptor arm and a jib. The lower end of the swing arm is mounted to the main beam of the robotic arm. The hinge coupler mounts to the upper end of the crane or truck boom. The robotic arm is mounted on the swing arm so as to downwardly orient the insulators on the robotic arm. A lowermost end of each insulator is adapted for releasably holding an electrical bypass which may include a bus bar and electrical cable jumpers.