Mill Liner Bolt Extraction for Safer Shell Installation
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Solution Overview
Problem
The current method of securing mill liners using fasteners exposes operators to numerous hazards due to the confined and hazardous environment inside the mill, including uneven surfaces, poor visibility, falling objects, and difficult communication.
Innovation Solution
A method and system that retains a mounting bolt within the mill liner, allowing it to be aligned with a mill shell opening, where an extraction tool is used from outside to detach and pull the bolt through, securing a fastener to attach the liner without requiring the operator to enter the mill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator enters the mill to install fasteners, then the installation can be completed, but the operator is exposed to numerous safety hazards including falling objects, uneven surfaces, and poor visibility
Solution Approach 1:
The operator is extracted from the hazardous confined space environment. The fastener installation system is designed to be operated from outside the mill, removing the operator from exposure to falling objects, uneven surfaces, and poor visibility hazards while maintaining installation capability.
Solution Approach 2:
A robotic manipulator system acts as an intermediary between the operator and the fastener installation task. The robotic system with end effector performs the actual fastener installation inside the mill, while the operator controls it from a safe external location, bridging the gap between operator safety and task completion.
2Ease of operation
If traditional fastening methods are used with operator inside the mill, then direct control is maintained, but communication is difficult and visibility is poor
Solution Approach 1:
The system creates a virtual copy or digital representation of the mill interior environment, allowing the operator to see and control the robotic manipulator remotely with full visual feedback. This eliminates poor visibility and communication difficulties while maintaining precise control capability.
3Ease of manufacture
If reline personnel climb up the mill shell to install bolts, then fastener installation is achieved, but workers are exposed to heights and working machinery
Solution Approach 1:
The installation capability is extracted from the human operator and embodied in a robotic system. The robotic manipulator can position and install fasteners without personnel needing to climb the mill shell or work at heights, eliminating exposure to falling objects and moving machinery while maintaining installation functionality.
4Manufacturing precision
If the mounting bolt is retained within the liner opening, then alignment with mill shell opening is facilitated, but the bolt must be detached and pulled through from outside the mill
Solution Approach 1:
The robotic manipulator with specialized end effector serves as an intermediary tool to perform the extraction operation. The system grasps the mounting bolt from outside the mill and pulls it through the mill shell opening, enabling the bolt to be retained for alignment purposes while still allowing extraction through automated external operation.
Data Source
AI summary
The present disclosure relates to a method for use in installation of a mill liner, the method including (a) retaining a mounting bolt at least partially within a liner opening extending through the mill liner, (b) positioning the mill liner against a mill shell so that the retained mounting bolt is aligned with a mill shell opening extending through the mill shell, (c) selectively coupling an extraction tool to the mounting bolt, the coupling performed by an operator outside of the mill shell, (d) detaching the mounting bolt from the liner using the extraction tool; (e) pulling the mounting bolt through the mill shell opening so that at least a portion of the mounting bolt protrudes outside of the mill shell, and, (e) securing a fastener onto the mounting bolt to thereby attach the mill liner to the mill.