Root Insert Stopper Insertion With Guided Piston Alignment
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Solution Overview
Problem
Conventional methods for inserting stoppers in metal root inserts of composite wind turbine blades are prone to user error, leading to mechanical failures and increased assembly time, and are not visually assessable, posing safety risks and inefficiencies.
Innovation Solution
A system comprising a chassis with a bottom plate, pillar, struts, top cover, absorber clamp, and piston, equipped with sensors and a limit switch, is used to accurately and repeatably insert stoppers into metal root inserts, ensuring proper positioning and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual insertion method is used, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to user error and positioning errors
Solution Approach 1:
The patent replaces the manual mechanical insertion system with an automated piston-driven mechanical system. The piston mechanically pushes the stopper into the root insert with controlled force and precision, eliminating human error while maintaining mechanical simplicity through standardized components like the piston, clamp, and alignment features.
Solution Approach 2:
The system incorporates self-alignment features where the piston and clamp automatically position themselves relative to the root insert during insertion. The alignment bearing and cylindrical bearing enable self-positioning without requiring precise manual alignment, allowing the system to service itself during the insertion process.
2Device complexity
If manual insertion method is used, then device complexity is reduced, but productivity deteriorates due to increased assembly time
Solution Approach 1:
The system performs preliminary alignment and positioning actions through the alignment bearing and cylindrical bearing before the actual stopper insertion. The piston is pre-positioned and the clamp is pre-aligned with the root insert, enabling rapid insertion without requiring time-consuming manual adjustment during the insertion process itself.
Solution Approach 2:
The automated piston system enables continuous insertion action without interruption. Once the system is activated, the piston continuously pushes the stopper into the root insert in a single uninterrupted motion, eliminating the start-stop nature of manual insertion and improving assembly speed through continuous useful action.
3Device complexity
If manual insertion method is used, then device complexity is reduced, but reliability deteriorates due to mechanical damage and safety risks
Solution Approach 1:
The alignment bearing and cylindrical bearing act as intermediary elements between the insertion system and the root insert. These intermediaries protect the root insert from direct impact and mechanical damage by providing controlled, gradual insertion while absorbing misalignment stresses, thereby improving reliability without requiring complex protective systems.
4Manufacturing precision
If automated insertion system is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The automated insertion system is segmented into distinct functional modules: the alignment bearing for positioning, the clamp for securing, the piston for pushing, and the limit switch for control. This segmentation allows each component to be simple and standardized while collectively achieving high precision, reducing overall system complexity through modular design.
Data Source
AI summary
A system for inserting a stopper in a metal root insert, the system comprising a chassis, the chassis having a bottom plate, a pillar extending perpendicularly therefrom to a second end, at least one strut having a first end and a top cover disposed at the second end of the at least one strut, the top cover disposed perpendicularly to the bottom plate, an absorber clamp extending perpendicular to the pillar, the absorber clamp having a circular bearing configured to hingedly close, a top clamp disposed at the second end of the pillar, and having a cylindrical bearing configured to vertically translate relative to the top clamp, a piston disposed below the top cover and configured to translate vertically through at least one of the bottom plate and the top cover and a limit switch operatively coupled to piston, the limit switch configured to detect a travel of the piston.