Liner fabrication tool
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Solution Overview
Problem
The existing methods for fabricating liner insulation systems in the boiler industry face challenges such as vibration and premature failure due to inadequate compression and maintenance costs, particularly when using non-threaded pins, which require manual force and additional tools like pry bars for assembly.
Innovation Solution
A liner fabrication tool with a gripper member that engages over the pin, utilizing a pivotally engaged axle and cam support members to apply compression force to the inner liner and insulation, allowing for secure welding without the need for tack welding or pry bars, enabling efficient assembly on various surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If non-threaded pins with manual clamping devices are used to assemble the liner and insulation system, then the device complexity is reduced, but the manufacturing precision and compression consistency deteriorate
Solution Approach 1:
The tool uses a spring-loaded mechanism that automatically applies consistent compression force when the handle is activated, eliminating the need for manual force application and ensuring uniform compression across all pin locations without requiring operator skill or strength
Solution Approach 2:
The spring mechanism provides a predetermined, consistent compression force parameter that is applied uniformly to all pins, ensuring manufacturing precision and compression consistency while keeping the device relatively simple in design
2Force
If additional tools like pry bars are used to compress the liner and insulation, then the compression force can be increased, but the ease of operation deteriorates
Solution Approach 1:
The tool combines the compression force application and welding positioning functions into a single integrated device, eliminating the need for separate pry bars and other auxiliary tools, thereby maintaining ease of operation while providing sufficient compression force
Solution Approach 2:
The spring-loaded mechanism automatically generates and applies the necessary compression force without requiring the operator to manually apply force with pry bars or other tools, making the operation convenient and straightforward
3Force
If tack welding is required to attach pry bars to pins for compression, then the compression process can be performed, but the productivity deteriorates
Solution Approach 1:
The tool extracts the compression function from the welding process entirely, using a mechanical spring-loaded mechanism to apply compression force without requiring any tack welding or attachment of auxiliary tools, thereby eliminating time-consuming welding steps and improving productivity
Solution Approach 2:
The spring mechanism is pre-loaded with compression force, allowing immediate application of compression when the handle is activated, eliminating the need for preliminary tack welding to attach compression tools to the pins
4Device complexity
If manual force application is used to compress the liner and insulation, then the equipment cost is reduced, but the reliability deteriorates
Solution Approach 1:
The spring-loaded mechanism automatically applies consistent, predetermined compression force without relying on operator skill, strength, or technique, ensuring reliable and repeatable compression results while keeping the device relatively simple in design
Solution Approach 2:
The tool uses a spring mechanism with predetermined force parameters that ensure consistent compression across all assemblies, improving reliability by eliminating variability introduced by manual force application while maintaining equipment simplicity
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 tool ensures consistent and secure compression of the liner and insulation system, reducing vibration and maintenance costs by allowing for one-handed operation and direct welding, thus enhancing the assembly process and system stability.
Implementation Method 1
rotation of the handle in a forward direction applies leverage against the first cam support member and the second cam support member to bind the pin in the opening and compress the liner and insulation system
Data Source
AI summary
A liner fabrication tool includes a handle engaged to a first cam support and a second cam support where each of the cam supports has forward edge. An axle extends between the first cam support and the second cam support. A gripper is rotatably engaged to the axle between the first cam support and the second cam support. The gripper includes a first wall, a second wall, and a base extending between the first wall and the second wall, the base has an opening where the opening is positioned between and proximate to the forward edges. The opening receives a pin of a liner and insulation system where rotation of the handle in a forward direction applies leverage against the first cam support and the second cam support to bind the pin in the opening and compress the liner and insulation system immediately prior to welding.