Tank Shell Support Frames With Channeled Rollers for Butt-Joint Alignment
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Solution Overview
Problem
The existing methods for fabricating tanks face challenges in maintaining the desired circular cross-sectional shape of tank shells during assembly, leading to inefficiencies, increased fabrication times, and lower quality due to flexing under gravity and other forces, which complicates the alignment and welding of components.
Innovation Solution
The tank fabricating equipment employs a frame with extending arms and rollers that contact the tank shell above the horizontal centerline to maintain a circular shape, align adjacent components, and facilitate simultaneous rotation for precise welding, eliminating manual alignment errors and reducing labor-intensive processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual methods are used to fabricate tank shells, then flexibility in handling is maintained, but the tank shell cannot maintain its desired circular cross-sectional shape due to flexing under gravity, leading to poor alignment and welding quality
Solution Approach 1:
The fabrication equipment is divided into multiple independent frames (first frame, second frame, third frame) that can be positioned at different locations along the tank shell. Each frame carries rollers that independently support specific sections of the tank shell, allowing the system to handle large-scale fabrication while maintaining modular flexibility and precision.
Solution Approach 2:
Rollers are introduced as intermediary elements between the tank shell and the supporting frames. These rollers contact the outer surface of the tank shell and provide distributed support, preventing direct mechanical constraints that would complicate the structure while maintaining the circular cross-sectional shape through proper roller positioning and spacing.
2Manufacturing precision
If manual alignment methods are used for tank components, then equipment simplicity is maintained, but alignment accuracy between adjacent components deteriorates, increasing fabrication time and reducing productivity
Solution Approach 1:
The equipment performs preliminary alignment of adjacent tank components (such as tank shells and heads) before welding begins. The frames and rollers are positioned to pre-align the components in the desired circular configuration, ensuring that when welding starts, the components are already in precise alignment, eliminating the need for time-consuming manual adjustments during the welding process.
3Productivity
If traditional fabrication methods are used, then equipment simplicity is maintained, but labor hours and fabrication time increase significantly due to manual alignment and shape maintenance
Solution Approach 1:
The fabrication equipment is designed with multi-functional frames that can support multiple tank components simultaneously. The same frames that support tank shells can also support tank heads or other components, allowing a single equipment setup to handle the entire fabrication process for different component types, thereby increasing productivity without proportionally increasing equipment complexity.
Data Source
AI summary
A design for tank fabricating equipment and system comprises a frame supporting opposing arms for supporting one or more tank shells. The opposing arms pivotally engage opposing sides of the tank shells to force them into a circular cross-sectional shape. The arms are provided with rollers for aligning the tank shell with adjacent components during fabrication. In some embodiments, the rollers are provided with a circumferential channel to accommodate welding seams and to ensure alignment of butt joints.