Heavy Machinery Alignment Tool With Remote Hydraulic Positioning
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Solution Overview
Problem
Existing methods for aligning large machinery, such as gas turbines and generators, are time-consuming and dependent on operator skill, leading to inconsistent results and safety risks due to manual operation of jacking screws.
Innovation Solution
The use of hydraulic or electro-mechanic actuators controlled by a remote control unit to precisely move a top plate relative to a bottom plate, with a low-friction intermediate element and lever arms to achieve controlled, predictable movements, reducing manual intervention and enhancing safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation of jacking screws is used to align machinery, then the alignment process can be performed with simple equipment, but the alignment time is excessive and the quality depends 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 intervention, significantly reduces alignment time, and ensures consistent quality regardless of operator skill, while the control unit provides automated precision control.
Solution Approach 2:
The alignment system performs self-adjustment through automated control. The control unit receives input from measurement devices and automatically controls the hydraulic actuators to achieve precise alignment without requiring continuous manual intervention or high operator skill, making the system self-sufficient in the alignment process.
2Reliability
If manual operation of jacking screws is used, then equipment simplicity is maintained, but operator safety is compromised due to direct manual intervention
Solution Approach 1:
The patent replaces direct manual mechanical operation with remotely controlled hydraulic actuators. This eliminates the safety risks associated with operators working directly under or near heavy machinery during alignment, as all adjustments are made through automated hydraulic control from a safe distance.
Solution Approach 2:
The hydraulic actuator system serves as an intermediary between the control unit and the machinery alignment process. This intermediary mechanism allows precise control of heavy components without requiring direct manual contact, thereby protecting operators from potential injuries while maintaining control capability.
3Manufacturing precision
If automated hydraulic actuators are used to control top plate movement, then alignment precision and predictability are improved, but the device complexity increases
Solution Approach 1:
The control unit receives feedback from measurement devices that monitor the alignment status of the machinery. Based on this feedback, the control unit automatically adjusts the hydraulic actuators to achieve precise alignment. This closed-loop control ensures high precision while automating the complex control processes.
Solution Approach 2:
The patent uses hydraulic actuators to provide controlled, predictable movement of the top plate. Hydraulic systems offer precise control capabilities and can generate the necessary force for heavy machinery alignment, achieving high manufacturing precision through fluid power control.
4Duration of action of stationary object
If the low friction intermediate element is exposed, then mechanical simplicity is maintained, but contamination from dust, dirt and humidity reduces service time
Solution Approach 1:
The patent introduces a protective housing or enclosure that surrounds the low friction intermediate element. This protective structure acts as an intermediary barrier that prevents dust, dirt, and humidity from contaminating the intermediate element, thereby extending its service life without significantly complicating the overall device design.
Solution Approach 2:
The protective housing creates a controlled environment around the low friction intermediate element, isolating it from harmful external factors such as dust, dirt, and humidity. This inert environment protection allows the intermediate element to maintain its low friction properties and extend service time without requiring complex active protection systems.
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
This approach significantly reduces alignment time, improves precision, and minimizes operator risk by enabling closed-loop control and independent alignment in vertical, lateral, and axial directions, while protecting the low-friction element from dust and humidity.
Implementation Method 1
Between the bottom plate and the top plate a low friction intermediate element is arranged allowing a limited relative movement between the bottom plate and the top plate
Implementation Method 2
Making use of hydraulic or electro-mechanic actuators that move the top plate relative to the bottom plate
Data Source
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AI summary
Tools and a method for aligning large machinery are described allowing a more efficient and more precise alignment of large machinery.