Panel Support Apparatus with Movable Rollers for Horizontal Transfer
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Solution Overview
Problem
The existing methods for manoeuvring and supporting large, heavy naval vessel panels are inefficient and hazardous, requiring specialized cranes that are costly and can cause production bottlenecks, and involve significant health and safety risks due to the weight and size of the panels.
Innovation Solution
A method and apparatus that allows panels to be shifted horizontally from an upstream station to an in-feed pallet using a horizontal force, with extended surface contact for stable support and heat transfer, eliminating the need for cranes and utilizing movable roller elements for partial support and easy panel transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a crane is used to lift and manoeuvre large panels, then the panel can be transferred from upstream to downstream stations, but the equipment cost and operational complexity increase significantly
Solution Approach 1:
The patent removes the crane from the system entirely and replaces it with a direct push-transfer mechanism. The panel is pushed horizontally from the welding station directly onto the in-feed pallet without any lifting or complex manoeuvring equipment, thereby extracting the problematic crane component from the production system.
Solution Approach 2:
Instead of lifting the panel vertically with a crane and then moving it horizontally, the system inverts the approach by pushing the panel horizontally along the ground from the welding station directly to the pallet, completely reversing the traditional lift-then-move sequence.
2Reliability
If a specialist crane operator is required to manoeuvre panels, then safe panel transfer can be achieved, but production bottlenecks occur when the operator is occupied elsewhere
Solution Approach 1:
The system makes the panel transfer self-service by eliminating the need for a specialist operator. The horizontal push mechanism allows any worker to transfer panels independently, with each station being self-sufficient and not dependent on a centralized crane operator's availability.
Solution Approach 2:
The patent segments the panel transfer function from the centralized crane operation and distributes it to individual work stations. Each station has its own independent push mechanism, dividing the monolithic crane-dependent process into multiple autonomous, simpler operations.
3Reliability
If welding lugs are attached to panels for crane lifting, then the panel can be securely lifted, but additional manufacturing steps and time are required
Solution Approach 1:
The patent extracts the welding lug attachment step entirely from the fabrication process. By eliminating the vertical lifting requirement, the system removes the need for lifting lugs, thereby extracting this additional manufacturing step and its associated time and material costs.
4Ease of operation
If panels are supported only by wheels contacting the underside, then the panel can move along the fabrication line, but the support stability and heat transfer properties are insufficient
Solution Approach 1:
The patent transitions from one-dimensional point contact support (wheels) to two-dimensional surface contact support. The in-feed pallet provides extended surface contact across the panel's bottom surface, adding dimensional support stability while maintaining ease of movement.
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 approach reduces capital equipment costs, eliminates the need for specialist operators, and enhances manufacturing efficiency by providing a safer and more direct material flow, while maintaining panel stability and facilitating heat dissipation during welding.
Implementation Method 1
an array of roller low friction elements movable between a raised position in which they contact the lower surface of the panel element and a lowered position in which they are spaced from the panel element
Implementation Method 2
the provision of extended surface to surface contact gives a robust structural support
Implementation Method 3
The term 'extended surface contact' is used to mean that, in general, at least 40% of the lower surface of the panel element is in surface contact with the work piece support surface... which greatly facilitate fabrication
Data Source
Figure 1
Figure 2~3
AI summary
A large and massive panel (12) is manoeuvred and supported by means of a work piece support (10) which has an upper horizontal work piece support surface (22) for receiving the panel in extended surface-to-surface contact. An array of apertures (24) is provided in the work piece support surface, beneath same of which are provided low friction bearing elements (28) moveable between a raised, load-bearing position in which the panel can be slid onto the work piece support and a retracted position in which the panel is left in extended surface to surface contact with the work piece support.