Manway Cover Alignment Tool for Hinge Deflection
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Solution Overview
Problem
The removal and reinstallation of heavy manway covers, which are often misaligned due to hinge deflection, pose a safety risk as they require significant effort to realign fastener openings during reattachment.
Innovation Solution
A manway cover alignment tool with a body/flange alignment tool plate, an alignment support structure, a cover attachment plate, and a height adjuster, allowing for adjustable alignment of manway cover bolt openings with corresponding manway flange bolt openings, ensuring proper alignment and safe reattachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If portable hinges are used to support the manway cover after removal, then the manway cover can be supported, but the weight of the cover causes the hinge to deflect too much such that the fastener openings no longer align
Solution Approach 1:
The alignment tool acts as an intermediary device between the manway cover and the portable hinge. It includes a cover attachment plate that connects to the cover, an alignment support structure that spans from the cover to the hinge, and a height adjuster that mediates the deflection by allowing vertical adjustment. This intermediary structure compensates for hinge deflection and maintains proper alignment of fastener openings throughout the operation.
2Ease of operation
If the fastener openings are misaligned due to hinge deflection, then the cover can be supported, but the fasteners cannot be inserted and the cover cannot be re-attached without great effort
Solution Approach 1:
The alignment tool performs preliminary alignment action before the actual reattachment process. By establishing proper alignment of the fastener openings through the adjustable support structure, the tool ensures that when the time comes to insert fasteners and secure the cover, everything is already positioned correctly. This preliminary alignment action eliminates the need for great effort or complex adjustment maneuvers during reattachment.
3Productivity
If brute force is used to remove the cover, then the cover can be removed, but it places workers in danger due to the weight of the cover
Solution Approach 1:
The alignment tool serves as a safety intermediary that distributes and manages the heavy loads involved in cover removal and reattachment. Rather than requiring workers to manually lift or force the heavy cover, the tool's support structure and height adjuster mechanism bear and control the forces, significantly reducing the safety risks to workers while maintaining operational efficiency.
Data Source
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AI summary
An alignment tool device for use in aligning a manway cover to a manway body/flange during installation of the manway cover includes a body/flange plate having a flange plate body with a plurality of flange plate openings and an alignment support structure, a cover plate having a cover plate body with a plurality of cover plate openings, and a height adjuster extending through the alignment support structure where the height adjuster is adapted to change a position of the cover plate relative to the flange plate to substantially align the manway cover openings with corresponding manway flange openings.