Modular Pipe Loader Assembly Independent Shuttle Arm Control
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Solution Overview
Problem
Existing horizontal directional drilling machines face challenges with weight distribution and efficiency due to interconnected pinion gears between shuttle arms, which add unnecessary weight and limit space for other components, and misalignment issues during pipe handling.
Innovation Solution
The use of independent shuttle arms with non-contact absolute rotary encoders and hydraulic actuators, allowing for synchronized movement without a connecting shaft, and a controller to manage velocity adjustments based on real-time sensor feedback to maintain alignment and optimize operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If interconnected pinion gears are used between shuttle arms, then synchronized movement is achieved, but machine weight increases and space for other components is reduced
Solution Approach 1:
The patent removes the connecting shaft and intermediate pinion gears from the shuttle arm system. Each shuttle arm is driven by its own motor, eliminating the need for mechanical synchronization mechanisms and reducing overall machine weight while maintaining synchronized operation through electronic control.
Solution Approach 2:
The patent replaces the mechanical synchronization system (connecting shafts and pinion gears) with an electronic control system. Motors are controlled independently through electronic signals, allowing synchronized movement without mechanical linkages, thereby reducing weight and improving flexibility.
2Stability of the object's composition
If interconnected pinion gears are used between shuttle arms, then synchronized movement is achieved, but device complexity increases
Solution Approach 1:
The patent eliminates the complex mechanical synchronization mechanism by removing the connecting shaft and pinion gears. The system uses independent motors controlled by a controller, simplifying the overall device architecture while achieving synchronized operation through electronic control.
Solution Approach 2:
The patent substitutes the complex mechanical linkage system with an electronic control system. Independent motors are controlled through electronic signals rather than mechanical connections, reducing device complexity and improving maintainability.
3Weight of moving object
If independent shuttle arms are used, then machine weight is reduced and space is freed, but alignment precision may be compromised
Solution Approach 1:
The patent incorporates sensors that provide feedback on shuttle arm position and alignment to the controller. The controller uses this feedback to adjust motor commands, ensuring precise alignment is maintained even with independent shuttle arms and reduced mechanical linkages.
Solution Approach 2:
The patent replaces mechanical alignment mechanisms with electronic control and sensing systems. Sensors detect position and alignment deviations, and the controller adjusts motor operation to maintain precision, achieving alignment control without mechanical linkages.
4Adaptability or versatility
If independent shuttle arms are used, then operational flexibility is improved, but control complexity increases
Solution Approach 1:
The patent uses a universal controller that manages multiple independent motors and sensors through a single integrated system. The controller handles various operational modes and coordination tasks, providing flexible control without proportionally increasing complexity through standardized control architecture.
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
Enhances weight distribution, reduces machine weight, improves operational efficiency, and ensures precise alignment of shuttle arms, thereby optimizing pipe handling and overall drilling performance.
Implementation Method 1
a first actuator configured to power movement of the first shuttle arm along the first shuttle path
Implementation Method 2
The use of independent shuttle arms with non-contact absolute rotary encoders and hydraulic actuators
Data Source
AI summary
A horizontal directional drilling machine having a modular pipe loader system. The system comprises a first and second pipe loader assembly supported on a drill frame. Each assembly supports a shuttle arm. The shuttle arms are configured to move independently of one another along a shuttle path that is traverse to a longitudinal axis of the drill frame. Movement of each shuttle arm is powered by an actuator supported on each pipe loader assembly. Each pipe loader assembly includes a sensor used to measure parameters related to the position of each shuttle arm relative to the drill frame. A controller analyzes the measured parameters and directs operation of each actuator in order to keep the shuttle arms moving in unison during operation.