Portable Reconditioning Jig for In-Situ Heavy Workpiece Machining
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Solution Overview
Problem
The challenge of reconditioning heavy parts in hydroelectric and wind turbines is hindered by their size and weight, making in-situ repairs difficult, leading to costly and time-consuming transportation to external sites, resulting in significant losses in electricity production due to prolonged turbine downtime.
Innovation Solution
A portable and storable precision reconditioning apparatus that allows for in-situ reconditioning using a jig and precision robotic arm, aligned with laser tools to ensure accurate positioning and machining of heavy workpieces, minimizing the need for external transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heavy parts are transported to external reconditioning sites, then reconditioning can be performed with specialized equipment, but transportation costs increase and downtime extends
Solution Approach 1:
Instead of transporting the workpiece to the equipment, the invention brings the reconditioning equipment to the workpiece location. The portable machining center is transported to the hydroelectric plant and positioned adjacent to the turbine hall, reversing the conventional logistics flow to eliminate transportation of heavy parts while maintaining reconditioning capabilities
Solution Approach 2:
A beam bridge is constructed as an intermediary structure extending from the turbine hall to the portable machining center. This beam serves as a mediator that allows the heavy turbine part to be moved a short distance to the reconditioning site without requiring full external transportation, while the beam itself becomes part of the support structure for the machining equipment
2Manufacturing precision
If heavy parts are transported to external sites, then specialized reconditioning equipment can be used, but transportation costs and complexity increase
Solution Approach 1:
The invention inverts the conventional approach by making the reconditioning equipment portable and transportable to the plant site, rather than transporting the heavy workpiece to fixed specialized equipment. This reverses the logistics complexity from transporting hundreds of tons of machinery to transporting a relatively small mobile machining center
Solution Approach 2:
The reconditioning system is segmented into modular components: a portable machining center that can be transported separately, a beam bridge that can be constructed on-site, and support structures that are assembled locally. This segmentation allows the complex reconditioning capability to be delivered in manageable parts without requiring complete external transportation infrastructure
3Reliability
If heavy parts are moved for reconditioning, then external expertise can be applied, but transportation risks and delays increase
Solution Approach 1:
By bringing the equipment to the workpiece rather than moving the workpiece to the equipment, the invention eliminates the hazardous transportation of heavy turbine parts through public roads, avoiding all associated risks of accidents, delays, and operational difficulties while maintaining the capability to perform quality reconditioning work
4Loss of time
If in-situ reconditioning is performed, then transportation time is eliminated, but positioning precision of the workpiece must be achieved
Solution Approach 1:
Before the actual reconditioning work begins, the portable machining center is precisely positioned relative to the turbine hall and the workpiece using preliminary measurement and alignment procedures. The beam bridge is constructed with pre-calculated dimensions and the machining center is aligned using measurement tools to ensure the workpiece can be accurately positioned and secured for machining operations
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 precise reconditioning of heavy parts within hydroelectric plants, reducing transportation costs and downtime, allowing for efficient resumption of electricity production while maintaining the functionality of the reconditioned parts.
Implementation Method 1
The alignment is performed with a laser alignment tool to obtain the required accuracy during this step
Data Source
AI summary
A method for the in-situ reconditioning of a heavy workpiece mounted on the floor. The method comprises assembling a jig mounted on the floor so as to be arranged around the workpiece to be reconditioned, that is also mounted on the floor, the jig supporting a gantry at the two ends of same, on which there is mounted a precision robotic arm carrying at least one machining apparatus. The method also comprises the alignment of the workpiece and the jig using a precision laser alignment tool in order to allow the jig, the gantry and the robotic arm to form a precision machining apparatus. The method also comprises the reconditioning of the workpiece using the precision machining apparatus.