Robotic Mill Liner Gripping Tool for Safe Bolt-Aligned Replacement
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Solution Overview
Problem
Existing methods for replacing mill liners in ore grinding mills require manual intervention, posing safety risks and inefficiencies due to the need for staff to handle heavy equipment and bolts, leading to prolonged maintenance and production losses.
Innovation Solution
A device or tool for gripping mill liners that allows automated and remote operation, featuring a rigid frame with adjustable claws and sensors for precise alignment and gripping, enabling secure handling and installation without human interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used for liner replacement, then staff can directly handle and position liners, but safety risks increase and maintenance time is prolonged
Solution Approach 1:
The automated manipulator system performs liner replacement operations autonomously without requiring manual intervention. The system uses sensors to detect liner positions, hydraulic actuators to manipulate bolts and liners, and a control system to coordinate all operations automatically, enabling the system to service itself and eliminate the need for human operators in the hazardous environment.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic manipulator system. The manipulator uses hydraulic actuators to perform bolt loosening, liner removal, and liner installation operations that were previously done manually, substituting human mechanical actions with automated mechanical systems to improve safety while maintaining operational efficiency.
2Extent of automation
If automated manipulator is used for liner replacement, then staff safety is improved and maintenance time is reduced, but device complexity increases
Solution Approach 1:
The manipulator system is designed with multi-functionality to perform multiple liner replacement operations (bolt loosening, liner removal, liner installation, bolt tightening) using the same robotic platform and tooling system. This universal approach consolidates what could be multiple separate systems into one integrated automated system, managing complexity through functional integration.
Solution Approach 2:
The patent introduces a control system as an intermediary between the operator and the complex manipulator system. The control system receives high-level commands, processes sensor data, and coordinates the various hydraulic actuators and manipulator movements, acting as an intermediary layer that manages the complexity of the automated system while presenting a simplified interface for operation.
3Force
If hydraulic equipment is used for liner manipulation, then gripping force is sufficient, but operation speed is limited
Solution Approach 1:
The hydraulic system operates using periodic cyclic actions rather than continuous operation. The hydraulic actuators perform rapid extend-retract cycles to manipulate bolts and liners, with each cycle providing sufficient gripping force during the extend phase and rapid repositioning during the retract phase. This periodic operation mode enables high-speed repetitive tasks while maintaining adequate force during the active gripping phases.
Solution Approach 2:
The manipulator system maintains continuous useful action by overlapping hydraulic cylinder operation cycles. While one hydraulic actuator is gripping or manipulating a bolt, another is already positioned for the next operation, and a third is retracting to reposition. This continuous overlapping of operational phases ensures that the system maintains high speed while each individual hydraulic action provides sufficient force.
Data Source
AI summary
A device or tool that is configured for gripping a liner in order to to remove the liner, and install the liner in the shell of a mill. The device includes, a rigid structure or frame forming a support for containing the components, a coupling element that allows the device to be secured or disposed on at least one end of a manipulation device, such as a robotic manipulator, and at least one claw or pincer for holding at least one bolt by the head. The tool is designed to allow the adjustment of the relative position thereof in order to align the pincers to the positions of the holes of each liner. The at least one claw is configured to allow the at least one claw to open and close so as to adjust the size of the claw opening to the size of the bolt being gripped. The at least one pincer or claw has at least one sensor, thereby enabling mill liners to be installed and removed.