Portable Flange Machining Tool With Rolling Support for Large Tubes
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Solution Overview
Problem
The cost and weight of traditional flange facers or circular mills become prohibitive for machining large tubular structures, such as wind turbine towers and pipelines, due to their size requirements.
Innovation Solution
A portable machine tool with a frame, tool head, and rollers that can be installed to rotate relative to the annular flange, allowing machining of large tubular structures by engaging and rolling along the flange faces, with adjustable components to fit various diameters and contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional flange facers or circular mills are used for large tubular structures, then machining capability is achieved, but cost and weight become prohibitive
Solution Approach 1:
The machine tool is divided into modular components including a frame assembly, tool head assembly, and roller assemblies that can be independently supported and positioned. This segmentation allows the system to maintain machining capability while reducing overall weight and cost compared to traditional monolithic designs.
Solution Approach 2:
Roller assemblies are introduced as intermediary elements that engage with the flange outer surface to provide stable support and enable rotation of the machine tool relative to the flange. This intermediary mechanism eliminates the need for heavy traditional support structures while maintaining machining precision.
2Manufacturing precision
If traditional flange facers or circular mills are used for large tubular structures, then machining capability is achieved, but cost becomes prohibitive
Solution Approach 1:
The machine tool employs segmented modular assemblies (frame, tool head, rollers) that can be manufactured independently using standard fabrication processes, reducing overall manufacturing cost while maintaining machining capability for large tubular structures.
Solution Approach 2:
The machine tool uses adjustable and reconfigurable components including variable diameter rollers and adjustable frame assemblies, allowing a single design to serve multiple flange sizes and applications, thereby reducing development and manufacturing costs.
3Productivity
If the machine tool rotates relative to the annular flange for machining, then machining efficiency is improved, but stability on non-planar surfaces becomes challenging
Solution Approach 1:
The roller assemblies are designed to locally adapt to the flange outer surface geometry through independent positioning and adjustment mechanisms. Each roller assembly can accommodate local variations in surface contour while maintaining stable engagement, enabling rotation and machining even on non-planar surfaces.
Solution Approach 2:
The machine tool incorporates dynamic adjustment capabilities where roller positions and orientations can be adjusted during operation to maintain stable contact with the rotating flange, ensuring consistent machining quality despite surface irregularities.
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
Enables efficient machining of large tubular structures with reduced costs and weight, ensuring precise and stable operation on non-planar surfaces.
Implementation Method 1
a plurality of rollers operatively supported by the frame and positioned to operatively engage and roll along one of the inward face or the outward face of the annular flange
Data Source
AI summary
Portable machine tools for machining an annular flange comprise a frame, a tool head operatively supported by the frame and positioned to operatively machine the outer annular surface of the annular flange, and a plurality of rollers operatively supported by the frame and positioned to operatively engage and roll along one of the inward face or the outward face of the annular flange. The portable machine tool is configured to be operatively installed to rotate relative to the annular flange for machining the outer annular surface of the annular flange with the tool head. Methods of machining annular flanges also are disclosed.