The present teachings relate to the field of industrial manufacturing such as the manufacture of aircraft and, more particularly, to a system that is sufficient to transport heavy objects through enclosed or tight spaces.
Industrial manufacturing of vehicles such as aircraft or other manufactured structures often requires moving heavy loads through enclosed or tight spaces. For example, after an initial assembly of an aircraft airframe, bulky and/or heavy articles or loads such as electrical power distribution systems (i.e., power panels) or other items or objects must be moved through the airframe to their final location. These loads must often be carried manually by assembly personnel, for example, because the floor of the aircraft is uneven and transporting the item with a dolly or other transportation aid is not possible.
Additionally, heavy objects such as power panels may require two or more assembly personnel so that the weight is distributed across workers, and a coordinated effort within the tight spaces of the aircraft and around corners can be difficult. Damage of aircraft structures is exceedingly common and requires repairs to be performed, which is time consuming and expensive. Further, injury to assembly personnel from tripping and carrying awkward, heavy loads through confined spaces can occur. In tight spaces such as aircraft airframes, often there is not sufficient vertical space to locate a motor and winch assembly above a top hook, cable and load, and the load cannot be lifted high enough or the system cannot be used in a tight space. Also, control of a crane winch is often difficult because the motor is placed at a location that is distant from the operator and the lifted object. Systems for moving a heavy load may be difficult and time-consuming to install and uninstall.
A structure and method that allows for simplified transportation of an object through tight spaces, such as a power panel through an airframe, that has a fast setup time would be desirable.
The following presents a simplified summary in order to provide a basic understanding of some aspects of one or more embodiments of the present teachings. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its primary purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description presented later.
In an embodiment, a rail fixture can include a plurality of rail sections including a first rail section, a second rail section, and at least a third rail section, at least two rail hangers configured to suspend the plurality of rail sections from a rail support structure, and at least one trolley including at least three roller wheels and a load support configured to support a load to be moved using the rail fixture. The trolley may be configured to traverse the plurality of rail sections, the first rail section and the second rail section may be connected together and configured to articulate with each other and to form a varying first angle during movement of the load to be moved, and the second rail section and the third rail section may be connected together and configured to articulate with each other and to form a varying second angle during movement of the load to be moved. The rail fixture may further include a first articulating joint connecting the first rail section and the second rail section together, and a first seam at an interface of the first rail section and the second rail section at the first articulating joint, as well as a second articulating joint connecting the second rail section and the third rail section together, and a second seam at an interface of the second rail section and the third rail section at the second articulating joint, wherein a centerline of each roller wheel is configured to roll across the first seam and the second seam. The first rail section and the second rail section may be configured such that the first angle decreases during an increase in the second angle, and the first angle increases during a decrease in the second angle.
In an embodiment, the rail fixture may include at least one track section and at least two travelers attached to the at least two rail hangers, wherein the at least two travelers are configured to traverse the at least one track section as the first rail section and the second rail section articulate with each other and as the second rail section and the third rail section articulate with each other. Each rail hanger may further include a hanger frame having an opening therein and a carabiner rotatably attached to the hanger frame. The rail fixture may further include at least one stopper plate including a first leg and a second leg, wherein the second leg is shorter than the first leg, the stopper plate is rotatably attached to the carabiner, the stopper includes a first position that allows at least one of the travelers to be positioned on one of the track sections, and the stopper includes a second position that blocks one of the track sections to prevent at least one of the travelers from extending past an end of the track section.
In an embodiment, the track section may include a first lip and a second lip, and each traveler may include a first set of wheels that engage the first lip during movement of the load to be moved and a second set of wheels that engage the second lip during movement of the load to be moved. The at least one trolley may be configured to engage at least the second rail section as the first rail section and the second rail section articulate with each other and as the second rail section and the third rail section articulate with each other.
In an embodiment, the rail fixture may further include a first pin that connects the first rail section and the second rail section together, wherein the first rail section and the second rail section are configured to articulate by swiveling on the first pin, and a second pin that connects the second rail section and the third rail section together, wherein the second rail section and the third rail section are configured to articulate by swiveling on the second pin. The rail fixture may further include a strap attached to the load support and a motor attached to the strap, wherein the strap is configured to be attached to a load to be moved and the motor is configured move along the strap to lift the load to be moved during operation of the motor. The rail fixture may further include a load to be moved attached to the strap, wherein the rail fixture is configured to lift the load toward the plurality of rail sections during operation of the motor.
In another embodiment, a rail fixture can include a corner assembly having a first track section and a second track section, wherein the first track section intersects the second track section at an intersection. The corner assembly may include a first traveler configured to traverse the first track section and a second traveler configured to traverse the second track section, a first rail section connected to the first traveler by a first rail hanger, a second rail section connected at a first articulating joint to the first rail section, and a third rail section connected to the second rail section at a second articulating joint and further connected to the second traveler by a second rail hanger. The rail fixture may further include a trolley configured to traverse the first rail section, the second rail section, and the third rail section. The first traveler may be configured to be in a first position near the intersection when the first rail section is straight with the second rail section, and when the second rail section forms a 90° angle with the third rail section, while the second traveler may be configured to be in a second position away from the intersection when the first rail section is straight with the second rail section, and when the second rail section forms a 90° angle with the third rail section, where the second position is further away from the intersection than the first position. Further, the first traveler may be configured to be in a third position away the intersection when the first rail section forms a 90° angle with the second rail section, and when the second rail section is straight with the third rail section, while the second traveler may be configured to be in a fourth position near the intersection when the first rail section forms a 90° angle with the second rail section, and when the second rail section is straight with the third rail section, where the fourth position is closer to the intersection than the third position. In an embodiment, the first rail section and the second rail section may be attached at the first articulating joint, and the first articulating joint may be configured such that the first rail section can swivel on the second rail section. Further, the second rail section and the third rail section may be attached at the second articulating joint, and the second articulating joint may be configured such that the second rail section can swivel on the third rail section.
In another embodiment, a method for moving a load along a plurality of rail sections of a rail fixture can include attaching a load to be moved to a trolley, engaging a first rail section with the trolley, and rolling the trolley along the first rail section, off the first rail section, and onto a second rail section such that the trolley engages the second rail section, wherein the second rail section is attached to, and configured to articulate with, the first rail section. Further, with the trolley engaging the second rail section, the first rail section may be articulated with the second rail section such that a first angle formed by the first rail section and the second rail section decreases. Additionally, during the articulating of the first rail section with the second rail section, the method can include articulating the second rail section with a third rail section that is attached to, and configured to articulate with, the second rail section such that an a second angle formed by the second rail section and the third rail section increases.
The method may further include rolling the trolley along the second rail section, off of the second rail section, and onto the third rail section, such that the trolley engages the third rail section subsequent to the articulating of the first rail section with the second rail section and subsequent to the articulating of the second rail section with the third rail section. The first angle may be from 140° to 180° prior to articulating the first rail section and the second rail section, and the method may further include decreasing the first angle to from 90° to 130° during the articulating of the first rail section with the second rail section. The second angle may be from 90° to 130° prior to articulating the second rail section and the third rail section, and the method may further include increasing the second angle to from 140° to 180° during the articulating of the second rail section with the third rail section. The first angle may be decreased from 180° to 90° during the articulating of the first rail section with the second rail section, and the second angle may be increased from 90° to 180° during the articulating of the second rail section with the third rail section. During the articulating of the first rail section with the second rail section, a first traveler that is attached to the first rail section may be rolled along a first track section of a track and, during the articulating of the second rail section with the third rail section, a second traveler that is attached to the third rail section may be rolled along a second track section, wherein the first track section forms an angle of 90° with the second track section.
In an embodiment, the load to be moved may be attached to a motor, wherein the motor is attached to the trolley with a strap. The motor may be operated to lift the load to be moved along the strap and toward the plurality of rail sections. In an embodiment, operating the motor may include operating an electric drill.
The accompanying drawings, which are incorporated in, and constitute a part of this specification, illustrate embodiments of the present teachings and, together with the description, serve to explain the principles of the disclosure. In the figures:
It should be noted that some details of the FIGS. have been simplified and are drawn to facilitate understanding of the present teachings rather than to maintain strict structural accuracy, detail, and scale.
Reference will now be made in detail to exemplary embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
As described above, transporting a heavy object such as a power panel through an aircraft airframe is difficult, often results in damage to the aircraft and/or power panel, is typically completed manually by manufacturing personnel, and may result in injury to assembly personnel. Rolling the article or load across the floor of the aircraft using transportation equipment such as a dolly is not possible due to the uneven surface of the floor. Some specifications require that an employee may lift a maximum weight of less than 40 pounds, while a heavy load such as a power panel may weigh as much as 400 pounds, and transporting the load thereby requires a coordinated effort by several employees through tight spaces and uneven surfaces. Embodiments of the present disclosure may provide rail fixture that can be used to transport heavy objects through tight spaces. While the description below describes the present disclosure with respect to the transport of a power panel through an aircraft airframe, it will be understood that the transport of other objects, regardless of weight or bulk, through spaces other than an aircraft airframe is also contemplated.
The track section 108 may include a pair of horizontal shelves or lips 112 that extend laterally from each side along a length of the track section 108. The shelves 112 can be configured to support one or more travelers 114. The travelers 114 may include a set of traveler wheel assemblies 116 that engage, and are supported by, the shelves 112 of the track section 108, such that the travelers 114 freely traverse along a length of the track section 108 by rolling along the shelves 112. The traveler wheel assemblies 116 can include various subassemblies such as wheels, bearings, axles, etc. In an embodiment, each traveler 114 can include four traveler wheel assemblies 116, with two traveler wheel assemblies 116 positioned on each side of the track section 108. It will be understood that the wheel assemblies 114 and shelves 112 are merely one example of a mechanical assembly that allows the traveler 112 to traverse the length of the track section 108, and other mechanical assemblies are contemplated.
The rail section 120 can be configured to support one or more trolleys 122. The trolley 122 may include a set of trolley wheel assemblies 124 that engage, and are supported by, the rail section 120, such that the trolley 122 freely traverses along a length of the rail section 120 by rolling along the rail section 120. The trolley wheel assemblies 124 can include various subassemblies such as wheels, bearings, axles, etc. In an embodiment, each trolley 122 can include at least three trolley wheel assemblies 124, where at least two trolley wheel assemblies 124 are positioned on one side of the rail section 120 and at least one trolley wheel assembly 124 positioned on the other side of the rail section 120. The set of trolley wheels may further include two wheel assemblies 124 on each side of the rail section 120, or three or more wheel assemblies 124 on each side of the rail section. As the number of trolley wheel assemblies 124 increases, the trolley 122 may support a heavier weight. It will be understood that the trolley wheel assemblies 124 are merely one example of a mechanical assembly that allows the trolley 122 to traverse the length of the rail section 120, and other mechanical assemblies are contemplated.
A load 140, for example, a power panel, that is to be moved from a first location to a second location within an airframe 102 may be attached to the trolley 122 using a load hanger 142. The load hanger 142 may include a flexible strap 144 that is secured around a portion of the trolley 122, thereby supporting the load 140 and suspending the load 140 in the air and off the floor of the airframe 102.
In one embodiment to install the rail fixture 100, assembly personnel may set up a number of track sections 108 through the airframe 102, from the second (ending) location to the first (starting) location. Each track section 108 may be attached using one or more pliant hangers 104, for example, one or more straps 104 secured around the airframe 102 with cam buckles 106. The number of track sections 108 required may depend, at least in part, on the weight of the load 140 being moved and the number of turns, such as 90° turns, that must be made through the aircraft while moving the load from the first location to the second location.
As depicted in
Each rail section 120 can be removably connected to another rail section 120 at an articulated joint that uses a pin 180 which extends from tongue at one end of one rail section 120 into a hole 182 through a tongue of another rail section 120. The pin 180 extends downward through the hole 182, and thus gravity and the weight of the load 140 as it passes across the joint between two rail sections 120 is sufficient to prevent the two rail sections from separating.
After the plurality of track sections 108 and the plurality of rail sections 120 are installed, the trolley 122 can be rolled over an end of the first rail section 120 at the first location, and the load hanger 142 can be attached to the trolley 122.
In this embodiment, the load 140 includes a power panel 140. To move the power panel 140, the strongback 150 and the motorized winch assembly 146 is attached to the power panel 140. The flexible strap 144 is fed through the opening at the end of the hollow tube 152 such that it physically contacts the first roller 154, fed through the hollow tube 152, then positioned around the second roller 156 and through the slot 158 in the hollow tube. The end of the flexible strap 144 is then attached to the take-up reel 160. The motor 166, which may be conveniently supplied using the battery-powered electric drill as depicted, is engaged to operate the gearbox 164 which, in turn, rotates the take-up reel 160. The strap 144 is reeled in on the take-up reel 160, which lifts the strongback 150 to which the winch assembly 146 is attached, along with the power panel 140, off the floor of the airframe 102 and toward the rail fixture 100, thereby suspending the power panel 140 in the air. The winch assembly 146 is described in more detail below with reference to
Subsequently, the trolley 122 can be rolled along the plurality of rails 120 from the first location to the second location. During relocation of the load 140, the travelers 114 can rolled along the track sections 108 and, because the rail fixture 100 is not rigidly attached to the airframe 102, the rail fixture 100 is able to be repositioned to move the load 140 laterally around walls and other structures of the airframe 102. Because the travelers 114 and the trolley 122 are open at the top, they may respectively roll past the track hangers 110 and the rail hangers 118.
Even though the rail fixture 100 is not rigidly attached to the airframe 102 and has a degree of movement available during transport of the load 140, rolling the trolley 122 around a bend or corner such as a 90° corner can prove difficult. In attempting to traverse around a corner, an arcuate corner rail section that has an excessively short radius makes it difficult or impossible to roll the trolley 122 freely around the corner. Further, an arcuate corner rail section may not be easily supported around the entire radius. A particularly heavy load such as a power panel may cause an arcuate corner rail section to droop or sag such that the power panel physically contacts the floor of the airframe 102 without readjustment of the strap or hanger.
As depicted in
In the
Thus in
During use of the corner assembly 300, the trolley 122 of
After articulating the corner assembly 300 to the
Subsequently, the trolley 122 may be rolled from the second rail section 312 onto the third rail section 316 to complete the movement of the power panel 140 around the 90° corner as depicted in
It will be appreciated that the corner assembly 300 of
In
During use of the rail fixture 100, the wheels 124 of the trolley 122 physically contact an upper half of the first rail section 702 and the second rail section 704. To maintain the trolley 122 on the rail sections 702, 704 during transfer of the load 104 across the rail sections of the rail fixture 100, a lateral spacing 900 (
During transfer of the load 140 across the plurality of rail sections 702, 704, bumping and jarring of the load 140 is to be avoided, which could occur as the trolley 122 passes across the joint 700 between the first rail section 702 and the second rail section 704. However, the ends of the rail sections 702, 704 and the operation of the trolley 122 may be configured as described herein to reduce jarring of the trolley 122, and thus to reduce jarring of the load 140 as the trolley 122 passes across the joint 700. For example, as shown in
As depicted in
Additionally, in
With the embodiment of
In either of the embodiments of
As depicted in
To prevent the traveler 114 from inadvertently rolling off of the track section 108 during transport of the load 140, the rail fixture 100 may include a stopper 170 as described above with reference to
After placing the traveler onto the track section 108, the track section 108 is lowered which, through gravity or manual rotation, rotates the carabiner 110 into the closed position as depicted in
In this embodiment, the second legs 1012 are shorter than the first legs 1010. When the stopper 170 is placed into the open position as depicted in
It will be understood that the description and depiction of the winch assembly 146 is simplified for purposes of explanation. For example, the gearbox 164 will likely include many additional gears of differing gear ratios, for example, to increase the torque applied to the take-up reel by the motor to enable a relatively low torque motor 166 such as a battery powered electric drill to lift a relatively heavy load 140 such as a power panel, as well as the durability and longevity of the gearbox 164. In an embodiment, the gear box may have a gear ratio in the range of from 30:1 to 120:1, for example, 60:1. Worm gearboxes having a sufficient gear ratio are available from Ondrive. US Corp. of Freeport, New York, for example, model P45-60.
To install the rail fixture 100, a first track section 1306 and a second track section 1308 are suspended from the airframe 102 as described above. Next, the first traveler 1302 is positioned on the first track section 1306, and the second traveler 1304 is positioned on the second track section 1308, as described above. Subsequently, one or more additional track sections 1310 are suspended from the airframe 102, and one or more rail sections 1312 are attached to the track sections 1310. As described above, rail sections 1312 may include a traveler 114 at one end, and no traveler at the opposite end. The end attached to the traveler 114 will be positioned underneath the adjacent rail section end with no traveler, while the end with no traveler 114 will be positioned over an adjacent rail section end having a traveler 114 attached thereto.
In the exemplary depiction of
Thus the rail sections 1312, 316 leading away from end rail section 1300 have an end closest to end rail section 1300 with no traveler, and an end furthest away from end rail section 1300 with a traveler. Continuing down the rail fixture 100 away from end rail section 1300, once an unsupported middle rail section 312 of a corner assembly 300 is encountered, the end of the next rail section 310 closest to the end rail section 1300 has a traveler attached thereto. Thus rail section 310 leading away from end rail section 1300 has an end closest to end rail section 1300 with a traveler, and may have an end furthest away from end rail section 1300 with no traveler, unless rail section 310 is part of a second corner assembly 300 or is an end section at the first location, in which case it may have a traveler attached at both ends similar to end rail section 1300.
As depicted, some track sections 1306, 1308 may be shorter than other track sections 1310, 306 and some rail section 312 may be shorter than other rail sections 316. After installing all track sections, rail sections, and corner assemblies, the trolley 122 may be positioned on the first rail section, the load 144 may be attached to the trolley 122 and lifted into position suspended from the trolley 122, for example, using the winch assembly 146, and then moved from an initial starting first location to an ending second location at end section 1300, where it is then installed in its final location.
The materials used to manufacture each of the components of the rail fixture 100 and the dimensions of each component depend, for example, on the stresses encountered during transport of the load 140 which, in turn, depends on the anticipated weight of the load. The system may be designed to support and transport a load having an anticipated weight, plus any additional tolerance. Various materials may be used in the manufacture of the rail fixture, for example, steel, aluminum, iron, metal alloys, synthetic materials such as polymers, etc. A sufficient rail system in accordance with an embodiment of the present teachings may be designed and manufactured by one of ordinary skill in the art from the description herein.
The rail fixture described herein thus provides a system that may be used to support and move a relatively heavy object through a relatively confined or tight space such as an aircraft airframe across long span distances. The rail fixture is relatively quick to install, disassembly, and remove from the assembly location without undue time or effort. The plurality of travelers 114 and movable hangers 104, 118, 144 allow lateral and omnidirectional movement of the rail sections 120 during movement of the load 140 from a first location to a second location, and around corners such as 90° bends. The articulating rails can be adjusted during load movement, and can articulate or snake around obstacles, which straight rails or a fixed system cannot. The rail system may be suspended without using struts and may hang from existing structures. The winch assembly 146 allows the load 140 to be lifted using a motor. The rail fixture may thus reduce injury to assembly personnel as well as damage to the airframe and power panel, and may further reduce assembly costs. All rail sections may be straight and are not curved, but the load may still be moved in curved directions. The articulating round rails are connected in such a way that the loaded trolley transfers between rail sections with little or no bump, divot or obstruction. With the winch assembly described herein, the motor and winch are physically located on the weight that is being lifted, which improves control of the load. The space required for the motor, the winch, and the load is consolidated so the load can be lifted higher that a system which uses a crane or other winch system. Further, a single operator can manipulate the load while operating the lift motor.
Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present teachings are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein. For example, a range of “less than 10” can include any and all sub-ranges between (and including) the minimum value of zero and the maximum value of 10, that is, any and all sub-ranges having a minimum value of equal to or greater than zero and a maximum value of equal to or less than 10, e.g., 1 to 5. In certain cases, the numerical values as stated for the parameter can take on negative values. In this case, the example value of range stated as “less than 10” can assume negative values, e.g. −1, −2, −3, −10, −20, −30, etc.
While the present teachings have been illustrated with respect to one or more implementations, alterations and/or modifications can be made to the illustrated examples without departing from the spirit and scope of the appended claims. For example, it will be appreciated that while the process is described as a series of acts or events, the present teachings are not limited by the ordering of such acts or events. Some acts may occur in different orders and/or concurrently with other acts or events apart from those described herein. Also, not all process stages may be required to implement a methodology in accordance with one or more aspects or embodiments of the present teachings. It will be appreciated that structural components and/or processing stages can be added or existing structural components and/or processing stages can be removed or modified. Further, one or more of the acts depicted herein may be carried out in one or more separate acts and/or phases. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” The term “at least one of” is used to mean one or more of the listed items can be selected. As used herein, the term “one or more of” with respect to a listing of items such as, for example, A and B, means A alone, B alone, or A and B. The term “at least one of” is used to mean one or more of the listed items can be selected. Further, in the discussion and claims herein, the term “on” used with respect to two materials, one “on” the other, means at least some contact between the materials, while “over” means the materials are in proximity, but possibly with one or more additional intervening materials such that contact is possible but not required. Neither “on” nor “over” implies any directionality as used herein. The term “conformal” describes a coating material in which angles of the underlying material are preserved by the conformal material. The term “about” indicates that the value listed may be somewhat altered, as long as the alteration does not result in nonconformance of the process or structure to the illustrated embodiment. Finally, “exemplary” indicates the description is used as an example, rather than implying that it is an ideal. Other embodiments of the present teachings will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the present teachings being indicated by the following claims.
Terms of relative position as used in this application are defined based on a plane parallel to the conventional plane or working surface of a workpiece, regardless of the orientation of the workpiece. The term “horizontal” or “lateral” as used in this application is defined as a plane parallel to the conventional plane or working surface of a workpiece, regardless of the orientation of the workpiece. The term “vertical” refers to a direction perpendicular to the horizontal. Terms such as “on,” “side” (as in “sidewall”), “higher,” “lower,” “over,” “top,” and “under” are defined with respect to the conventional plane or working surface being on the top surface of the workpiece, regardless of the orientation of the workpiece.
Number | Name | Date | Kind |
---|---|---|---|
3880087 | Pamer | Apr 1975 | A |
4062519 | Jacobs | Dec 1977 | A |
4492168 | Cellai | Jan 1985 | A |
5038900 | Durant | Aug 1991 | A |
5231932 | Enderlein | Aug 1993 | A |
6138574 | Zaguroli, Jr. | Oct 2000 | A |
6269904 | Morhaus | Aug 2001 | B1 |
6345578 | Pabst | Feb 2002 | B1 |
6360669 | Albrich | Mar 2002 | B1 |
6543366 | Pabst | Apr 2003 | B2 |
6745891 | Walter | Jun 2004 | B2 |
6758325 | Greeley | Jul 2004 | B2 |
8172073 | Luger | May 2012 | B2 |
9139206 | Quattlebaum | Sep 2015 | B2 |
9475503 | Fessler | Oct 2016 | B2 |
20080229967 | Lins | Sep 2008 | A1 |
20090293757 | Bischofberger | Dec 2009 | A1 |
20100107919 | Perakis | May 2010 | A1 |
20100288155 | Chepurny | Nov 2010 | A1 |