Remote Wear Part Handling for Safe Earthmoving Replacement
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Solution Overview
Problem
The replacement of wear parts on earth working equipment in remote and challenging environments is difficult due to environmental conditions, the weight and size of the parts, and the risks associated with manual handling and securing methods, which pose safety hazards to operators.
Innovation Solution
A mobile service vehicle equipped with a manipulator and controller, utilizing sensors and automated tools, allows for remote and controlled removal and installation of wear parts, with features like RFID encoding, database integration, and automated processes to ensure safe and efficient replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wear parts are replaced manually in the field, then the replacement can be performed in remote locations, but the operator safety is compromised due to heavy parts and uncontrolled falling
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system. A robot equipped with specialized end effectors performs wear part removal and installation, eliminating the need for operators to manually handle heavy components. The system uses automated positioning, gripping, and securing mechanisms to perform replacements safely in remote locations without compromising operator safety.
Solution Approach 2:
The patent introduces a robot as an intermediary between the operator and the heavy wear parts. The robot handles all dangerous operations including gripping, positioning, and securing of wear parts, while operators can monitor and control the process remotely. This intermediary system eliminates direct human contact with hazardous elements during wear part replacement.
2Weight of moving object
If traditional rigging systems are used to lift wear parts, then the heavy parts can be handled, but the rigging may slip or create pinch points endangering the installer
Solution Approach 1:
The patent replaces traditional rigging systems with a robotic manipulator system. The robot uses controlled gripping mechanisms and automated positioning to handle heavy wear parts without relying on cables, chains, or rigging equipment that can slip or create pinch points. The robotic system provides precise control and multiple points of contact for secure handling.
Solution Approach 2:
The robotic system performs self-positioning and self-adjustment during wear part handling. The robot can autonomously adjust its grip force, positioning, and orientation to securely handle heavy parts without external assistance or traditional rigging equipment, eliminating safety hazards associated with manual rigging operations.
3Strength
If operators manually secure wear parts with locks and retainers, then the wear parts can be attached to equipment, but the operator must come in close proximity creating potential risk
Solution Approach 1:
The patent replaces manual securing operations with a robotic system equipped with specialized end effectors. The robot performs all operations including positioning, gripping, and securing of wear parts with locks and retainers. The robotic system can work from a safe distance, eliminating the need for operators to come into close proximity with potentially falling heavy parts.
Solution Approach 2:
The robot serves as an intermediary that performs all close-proximity operations with wear parts. The robotic system handles positioning, securing, and locking operations while operators can monitor and control the process remotely, eliminating direct human exposure to hazards associated with securing heavy wear parts.
4Productivity
If wear parts are removed by letting them fall or using a hammer, then the removal can be performed quickly, but the operator is subjected to risks from uncontrolled movement
Solution Approach 1:
The patent replaces crude removal methods (dropping or hammering) with a controlled robotic system. The robot uses specialized gripping tools to securely hold wear parts during removal, providing controlled and predictable movement throughout the entire process. This eliminates the uncontrolled movement and safety risks associated with traditional removal methods while maintaining efficient operation.
Solution Approach 2:
The robotic system autonomously performs secure gripping, controlled positioning, and safe removal of wear parts without requiring operators to intervene in dangerous ways. The system can quickly and safely remove wear parts by itself, eliminating the need for operators to use hazardous methods like hammers or uncontrolled dropping.
Data Source
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AI summary
A process and tool for installing and removing various kinds of wear parts used with earth working equipment. The process and tool allows the operator to remove and install the wear parts at a safe distance so that the operator is physically remote from the potential risks of the removal and installation process. The tool may be manually operated via an operator or the tool may be a semi-automated or fully automated.