Rotary Jig Fabrication of Pressure Vessel Support Frames

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Solution Overview

Problem

The current manufacturing process for large support frames in pressure vessels is labor-intensive and prone to variability due to manual handling, welding, and machining, leading to inconsistent quality and potential rework.

Innovation Solution

A fabrication system comprising a jig assembly with a clamping system and workstations that supports and positions sub-elements for precise operations, such as welding and material removal, reducing manual interaction through a rotatable setup with positioning actuators and measurement systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual handling, welding and machining are used for sub-elements, then flexibility and adaptability are maintained, but manufacturing precision and quality consistency deteriorate

Engineering Contradiction:

Improvequality consistencyVSAvoidmanual interaction

Core Design Contradiction:

Manufacturing precisionVSExtent of automation

Solution Approach 1:

The patent replaces manual mechanical operations with automated robotic systems. Robots perform welding, handling, and machining tasks, eliminating variability in manual execution while maintaining the mechanical nature of these operations. This substitution directly improves quality consistency by ensuring uniform application of welding parameters, handling forces, and machining operations across all sub-elements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements automated control of critical process parameters including welding current, voltage, speed, and positioning accuracy. By precisely controlling these parameters through automated systems rather than manual adjustment, the process achieves consistent quality outcomes. The system monitors and maintains parameters within specified tolerances, ensuring repeatable results across production batches.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If manual operations are performed by multiple operators, then task completion is achieved, but time consumption increases due to handover and skill variability

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidhandover time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent implements continuous automated operations where robotic systems perform handling, welding, and machining without interruption or handover between operators. The automated cell operates continuously, with robots transitioning seamlessly between tasks and positions. This eliminates the downtime associated with manual handovers and maintains productive action throughout the entire manufacturing cycle.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent combines multiple discrete manual operations into an integrated automated manufacturing cell. Handling, welding, and machining functions that were previously performed by separate operators are merged into a single coordinated automated system. This integration eliminates handover time and enables continuous flow production, significantly improving manufacturing efficiency.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If a rotatable jig assembly with multiple workstations is used, then manufacturing precision and automation are improved, but device complexity increases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidsystem structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the manufacturing system into modular functional workstations (handling station, welding station, machining station) arranged around a rotatable jig assembly. Each workstation is a self-contained module with dedicated equipment and controls. This segmentation allows independent optimization of each station while maintaining overall system coordination, managing complexity through functional decomposition.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a dynamically rotatable jig assembly that can rotate to present different sub-elements or workstations to appropriate processing equipment. This dynamic reconfiguration capability allows a single physical platform to serve multiple functions at different times, reducing the need for multiple separate fixed installations and managing space and equipment complexity.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20240424618A1Fabrication system for the manufacture of a support frame for a pressure vessel, and method of manufacture of a support frame for a pressure vessel with provision of such fabrication system

Publication Date: 2024.12.26 BAE SYSTEMS PLC

AI summary

A fabrication system (100) for the manufacture of a support frame (10) for a pressure vessel (12). The support frame (10) is fabricated from a plurality of sub-elements (202, 204). The fabrication system comprises a jig assembly (300), a clamping system (400) mounted on the jig assembly (300) and the jig assembly (300) being rotatably mounted about a rotation axis (302), and extending out radially from the rotation axis (302) to an outer edge (304). A plurality of workstations (600, 602, 604) are arranged around the outer edge (304) of the jig assembly (300), located and configured to perform operations on the sub-elements (202, 204). The plurality of workstations (600, 602, 604) are mounted in a fixed position, the jig assembly (300) being rotatable about the rotation axis (302) relative to the workstations (600, 602, 604).