Zero-G Lift Assist for Precise Heavy Part Positioning
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Solution Overview
Problem
Positioning heavy parts accurately in confined spaces is challenging due to the significant force required to counteract gravitational forces, which can lead to operator fatigue and risk of damaging surrounding components during installation or rework.
Innovation Solution
A zero-G positioning device with a weight measurement mechanism, force sensor, controller, and drive mechanism that applies a countering force to establish a zero-gravity condition, allowing for precise movement and installation of heavy parts by sensing directional forces and adjusting velocity accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional lifting methods are used for heavy parts, then the part can be moved, but significant operator force is required leading to operator fatigue and risk of damage to surrounding components
Solution Approach 1:
The gravity compensation device generates an upward counteracting force equal to the gravitational force on the part, creating a zero-G condition. The force sensor detects the gravitational force magnitude, and the actuator applies an equal and opposite force to suspend the part, eliminating the need for operator force to counteract gravity.
Solution Approach 2:
The patent replaces manual mechanical lifting with an automated system comprising a force sensor, controller, and actuator. The force sensor electronically measures the gravitational force, the controller processes this data, and the actuator automatically applies the counteracting force, substituting human mechanical effort with an automated sensing and actuation system.
2Ease of operation
If zero-G assisting devices that suspend and lower parts are used, then operator effort is reduced, but they are not useful when space is a concern and parts need to be lifted or ascended into position
Solution Approach 1:
The gravity compensation device transitions from a static suspension system to a dynamic system that can both suspend and actively move parts. The actuator can adjust the counteracting force to not only balance gravity but also provide additional upward force to lift parts into confined spaces, making the device adaptable to various positioning needs in space-constrained environments.
3Manufacturing precision
If heavy parts are manually positioned, then no additional equipment is needed, but positioning accuracy is compromised and surrounding components may be damaged
Solution Approach 1:
The force sensor continuously monitors the gravitational force on the part and provides real-time feedback to the controller. The controller adjusts the actuator output based on this feedback to maintain precise force balance, enabling accurate positioning of heavy parts without manual handling that could cause damage or positioning errors.
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
Enables efficient and controlled handling and installation of heavy parts with reduced operator effort, minimizing damage to surrounding components and improving manufacturing efficiency by maintaining a zero-G state during movement.
Implementation Method 1
a weight measurement mechanism in communication with the part and further in communication with a support; a force sensor in communication with the support
Implementation Method 2
providing a countering force to the part; establishing a zero-G condition on the part
Data Source
AI summary
Apparatuses, systems, and methods are disclosed for providing a zero-G condition to a part to assist in allowing an operator to weightlessly move a part and assist an operator in the installation of a part into an assembly. Present methods, systems, and apparatuses further provide a zero-G lift able to alter the lift velocity of a part, from first predetermined velocity to a second predetermined velocity.