Extension Shaft Coupling Tool With Force-Sensed Linear Actuation

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Solution Overview

Problem

Existing tools for uncoupling and coupling extension shaft assemblies from control element assemblies in nuclear reactors are manual, time-consuming, and prone to causing damage due to the high forces required, especially when overcoming the bias of high-force retaining springs and 'sticktion' issues.

Innovation Solution

A tool comprising a support structure, a linear actuator, a microcontroller, a power source connector, a plunger shaft, and a sensor, which allows for controlled and precise uncoupling and coupling operations by actuating the linear drive to move the plunger shaft through specific strokes, while monitoring and managing the forces applied to prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual tools are used for uncoupling and coupling extension shaft assemblies, then device complexity is reduced, but productivity decreases and the risk of damage increases due to high forces required

Engineering Contradiction:

Improveuncoupling and coupling operation speedVSAvoidtool structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical operations with an automated linear actuator system. The linear actuator, controlled by a microcontroller, automatically positions the plunger shaft to overcome retaining spring bias and achieve uncoupling/coupling, eliminating the need for manual force application while increasing operational speed and precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The tool incorporates sensors that automatically detect the force required during uncoupling/coupling operations and provide feedback to the microcontroller. The system self-regulates the actuator's movement based on real-time force measurements, eliminating the need for external monitoring or manual adjustment while preventing damage from excessive forces.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If high forces are applied to overcome retaining spring bias and sticktion, then uncoupling and coupling operations can be completed, but the risk of damage to extension shaft assemblies increases

Engineering Contradiction:

Improveability to overcome retaining spring biasVSAvoiddamage risk to extension shaft assembly

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates force sensors that continuously monitor the force applied during uncoupling and coupling operations. The sensor data is fed back to the microcontroller, which adjusts the linear actuator's movement in real-time. This closed-loop feedback system ensures that sufficient force is applied to overcome retaining spring bias and sticktion while automatically preventing excessive forces that could cause damage to the extension shaft assembly.

Inventive Principle:

Principle #23Feedback

3Power

If air or hydraulic systems are used to provide the necessary force, then sufficient power is available, but device complexity and maintenance requirements increase

Engineering Contradiction:

Improveforce capability for uncoupling operationsVSAvoidsystem complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent replaces complex air or hydraulic force generation systems with a compact linear actuator driven by an electric motor. This substitution provides sufficient force for uncoupling operations while dramatically reducing system complexity, eliminating the need for compressors, hydraulic pumps, fluid reservoirs, and associated control valves, thereby reducing both initial complexity and maintenance requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The tool significantly reduces the time and effort required for uncoupling and coupling operations, minimizes the risk of damage to the extension shaft assemblies, and eliminates the need for air or hydraulic systems, thereby simplifying maintenance and reducing downtime.

Implementation Method 1

a linear actuator (110) comprising a linear drive (111) that is actuatable relative to the support structure (130) through an actuation stroke

Methodology Applied

Scientific EffectLinear actuator: Linear Motor

Implementation Method 2

The sensor (140) comprises a load cell

Methodology Applied

Scientific EffectLoad cell:

Data Source

PatentUS20250125062A1Shaft coupling and uncoupling tool

Publication Date: 2025.04.17 WESTINGHOUSE ELECTRIC CORP

AI summary

A tool for uncoupling and coupling an extension shaft assembly from a control element assembly of a nuclear reactor during reactor servicing is disclosed. The extension shaft assembly is transitionable between a coupled configuration where the extension shaft assembly is coupled to the control element assembly and an uncoupled configuration where the extension shaft assembly is uncoupled from the control element assembly. The tool comprises a support structure selectively attachable to the extension shaft assembly, a linear actuator, a microcontroller, a power source connector, a plunger shaft selectively attachable to the extension shaft assembly, and a sensor coupled to the microcontroller and the linear actuator. The sensor monitors a parameter indicative of a force experienced by the extension shaft assembly during at least one of a first actuation stroke or a second actuation stroke of a linear drive of the linear actuator.