Remote Wear Assembly Handling for Hazardous Retainer Service
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Solution Overview
Problem
The existing methods for removing and installing wear parts on earth working equipment, such as excavators, are hazardous and inefficient, especially in remote and unpredictable environments, due to the need for manual handling and securing of heavy components, which poses risks to operators and requires complex rigging systems.
Innovation Solution
A tool system that includes a manipulator and controller for remotely and safely installing and removing wear parts, using auxiliary tools and a cartridge for secure holding, and sensors for precise location and orientation, allowing for semi-automated or fully automated operation to reduce operator risk and improve efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual handling and securing methods are used for wear parts, then the equipment can be serviced in remote locations, but operator safety is compromised and the process becomes hazardous
Solution Approach 1:
A service vehicle equipped with a manipulator and auxiliary tools acts as an intermediary between the operator and the wear part. The manipulator remotely handles the wear part from the service vehicle, while the operator remains protected inside the vehicle, eliminating direct exposure to hazards while enabling remote location servicing.
Solution Approach 2:
The manual mechanical handling system is replaced with an automated manipulator system. The manipulator, controlled from the service vehicle, performs the mechanical operations of securing and manipulating the wear part, substituting the operator's direct mechanical interaction with the hazardous component.
2Ease of operation
If heavy wear parts are handled manually with rigging systems, then installation can proceed, but the complexity of the system increases and operator risk remains
Solution Approach 1:
The service vehicle combines multiple functions into a single integrated system: it provides operator protection, houses the manipulator mechanism, stores auxiliary tools, and serves as the base for wear part handling. This merging eliminates the need for separate rigging systems while maintaining installation capability.
Solution Approach 2:
The service vehicle is equipped with all necessary tools and mechanisms to perform wear part service operations independently. The manipulator and auxiliary tools on the vehicle enable self-sufficient wear part installation and removal without requiring external rigging equipment or additional personnel.
3Measurement precision
If operators work in close proximity to wear parts during installation, then precise positioning can be achieved, but the potential for injury from unsecured parts increases
Solution Approach 1:
The manipulator serves as an intermediary that precisely positions the wear part while keeping the operator at a safe distance. The manipulator's controlled movements enable accurate positioning without requiring the operator to be in close proximity to the potentially hazardous wear part.
Solution Approach 2:
The operator is extracted from the immediate hazard zone around the wear part. By controlling the manipulator from the protected service vehicle, the operator's physical presence is removed from the area where wear parts could fall or swing, eliminating direct exposure to these harmful factors while maintaining positioning control.
Data Source
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.