Modular Power Pack for Vacuum Pad Lifter
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Solution Overview
Problem
Existing vacuum material handlers for gantry crane operations are limited by the need for separate power packs for each vacuum pad, leading to increased weight and complexity, and lack of modularity, which restricts their efficiency and versatility in handling different pipe sizes.
Innovation Solution
A removably detachable, modular power pack that can be mounted directly to a vacuum pad or on host equipment, connected to multiple pads, and features an internal vacuum reservoir, allowing a single power pack to service multiple pads, with optional adjustable beams for accommodating various pipe sizes, and integrated safety features like indicator lights and a control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate power packs are used for each vacuum pad, then each pad has dedicated power supply, but weight and complexity increase
Solution Approach 1:
The power pack is designed as a universal unit that can service multiple vacuum pads through the modular adapter system. Each adapter connects to a specific pad configuration, but a single power pack can be moved between adapters to provide power to multiple pads, eliminating the need for dedicated power packs for each pad while maintaining reliable power supply.
2Reliability
If separate power packs are used for each vacuum pad, then each pad has dedicated power supply, but device complexity increases
Solution Approach 1:
The power pack serves multiple pads through the universal adapter interface, reducing the total number of power packs and associated mounting hardware needed. This modular approach simplifies the overall system architecture while maintaining the ability to provide dedicated power to each pad when connected.
3Stability of the object's composition
If fixed vacuum pad configurations are used, then structural stability is maintained, but adaptability to different pipe sizes decreases
Solution Approach 1:
The vacuum pad system is segmented into modular components: the main pad body, the adapter interface, and the power pack. This segmentation allows the adapter to be configured for different pad types while the main structure remains stable. The modular design enables adaptability to different pipe sizes through adapter selection without compromising the structural integrity of the primary lifting mechanism.
Solution Approach 2:
The system incorporates dynamic adaptability through the removable adapter configuration. While the main vacuum pad structure remains stable and fixed, the adapter interface can be changed to accommodate different pad configurations for various pipe sizes, providing the necessary versatility without sacrificing structural stability.
4Reliability
If multiple power packs are used to service multiple pads, then power availability is ensured, but weight and complexity increase
Solution Approach 1:
A single power pack can service multiple vacuum pads by connecting to different adapters mounted on the gantry or host equipment. This universal power pack design ensures power availability for multiple pads while reducing the total number of power packs needed, thereby decreasing system complexity and weight.
5Stability of the object's composition
If a beam is required to support vacuum pads, then structural stability is maintained, but weight and complexity increase
Solution Approach 1:
The adapter interface extracts the support function from a traditional beam structure, allowing vacuum pads to be mounted directly to the gantry or host equipment. This eliminates the need for separate support beams, reducing weight while maintaining structural stability through the direct mounting configuration.
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 modular design reduces weight and height, enabling faster cycles, improved lift ability, and safer remote operation by allowing a single power pack to service multiple pads, while accommodating different pipe sizes without the need for additional support beams, thus enhancing efficiency and versatility.
Implementation Method 1
an internal vacuum reservoir formed by the longitudinally extending vacuum structure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Embodiments of a vacuum material handler or lifting device and system of this disclosure provide a modular design that allows a power pack (3) to be mounted directly to the pad (10) or remotely mounted on host equipment to minimize lift weight. The pad, which includes an integral pad reservoir (7), may be arranged to accept a rotator or a tilting mechanism(4) for position when used on mobile equipment. The power pack is independent of the pad and can be transferred to multiple pads, thereby permitting a single power pack to service the different pads. The control mechanism (22) may reside on the pad to further facilitate modularity. Safety checks used for remote operation may be used to minimize the risk of danger in the event of remote vacuum hose (25) or vacuum failure.