Nuclear Vessel Bolt Handling With Self-Positioning Tool Carts
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Solution Overview
Problem
Current stud tensioning mechanisms in nuclear and sub-sea industries require pre-installation and manual placement of tools, which is not feasible in high-radiation, remote environments due to the size and complexity of fasteners, limiting the ability to correct malfunctions without manned intervention.
Innovation Solution
A remotely or autonomously operated bolt installation and removal system with a multi-rotating axis control scheme and modular tool carts that surround the nuclear vessel, allowing for the installation, tensioning, de-tensioning, removal, and storage of closure bolts, enabling efficient operation in high-radiation environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manually placed tooling is used for fastener tensioning, then installation can be performed, but the process requires pre-installation and manual intervention which is not feasible in high-radiation remote environments
Solution Approach 1:
The system employs self-positioning mechanisms where the automated tooling automatically aligns with and positions itself on the fasteners without requiring manual placement. The tooling includes self-adjusting alignment features that detect and lock onto the bolt locations autonomously, enabling fully remote operation in high-radiation environments while maintaining operational ease.
Solution Approach 2:
Manual mechanical placement operations are replaced with automated mechanical systems equipped with sensors, actuators, and control systems. The automated tooling uses robotic positioning mechanisms and computer-controlled alignment systems to perform functions previously requiring human operators, achieving both automation and operational simplicity.
2Strength
If large fasteners are used for nuclear vessel assembly, then structural strength is achieved, but the size and complexity preclude manned installation or intervention
Solution Approach 1:
The system uses self-positioning and self-aligning tooling that automatically detects large fastener locations and orientations without human intervention. The automated tools include self-adjusting mechanisms that adapt to the precise positioning requirements of large nuclear vessel fasteners, enabling installation of high-strength fasteners through fully automated remote operations.
Solution Approach 2:
The hazardous function of manual fastener installation is extracted from the system by removing human operators from the equation. The entire installation process is performed by automated robotic systems that can handle large, heavy fasteners and apply required torques without exposing personnel to radiation risks, thereby maintaining fastener strength while eliminating operational hazards.
3Reliability
If automated tooling is implemented for remote operation, then safety in high-radiation environments is improved, but system complexity increases
Solution Approach 1:
The automated tooling is designed as a multi-functional system that can perform multiple operations (installation, tensioning, inspection) with a single integrated platform. This universal tooling reduces the number of separate systems required, thereby managing complexity while maintaining high reliability through consistent, automated performance across all fastener operations in remote environments.
Solution Approach 2:
Multiple previously separate functions (positioning, alignment, fastener installation, torque application, and verification) are merged into a single integrated automated system. This consolidation reduces the overall system complexity by eliminating interfaces between separate systems while improving reliability through unified control and monitoring of all operations.
Data Source
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AI summary
A bolt installation and removal, BIR, system is used for assembling and disassembling a nuclear vessel. The BIR system includes a platform (210) with a stand for supporting the nuclear vessel. A track (204) extends around an outside perimeter of the platform and multiple tool carts (202) include wheels (208) that roll on the track. Tool towers (212) are located on the carts and include tool assemblies (214) configured to install and remove bolts (220) on the nuclear reactor vessel. Magazine towers (216) also extend up from the tool carts next to the tool towers and include magazines (218) that hold bolts for exchanging with the tool assemblies. Drive mechanisms (238) move tool heads in the tool assemblies around a first vertical axis, vertically up and down, and laterally to more simply and reliably install and remove the bolts in a radioactive underwater environment.