Patent Application
20140273751
The present invention is directed to a device and method for inspecting and/or finishing a surface of a work piece. In particular, the invention is directed to a device and method for inspecting and/or finishing the interior surface of tanks, vessels, containers and the like.
There are a variety of manufacturing procedures that require grinding, sanding, brushing, polishing, buffing or some other type of smoothing or finishing of surfaces. For example, large sheets of metal are welded together in the manufacturing of large metal tanks and the like. After the weld seam is cooled it is necessary to smooth the seam surface; failure to do so can result in nicks, scratches or other rough or uneven surfaces more prone to corrosion, difficult to clean and to disinfect than smooth ones.
As an example, surfacing requirements for new water tanks and other work pieces have become more stringent in recent years. In addition, the surface requirements for repainting welds on old tanks are much tighter now than the requirements which were in place when the tank was originally built. Consequently, during repair and repainting of the tanks, a large amount of grinding and other refinishing must be done. Therefore, removal of weld spatter and the grinding of rough welds on steel water tanks has become a critical component in meeting current specifications.
While many sizes of the tanks are in use, one such representative steel water tank has over one million of gallons of storage (1 MG). Such a tank would contain approximately 2,500 linear feet of exterior weld surface and approximately 4,500 linear feet of interior weld surface. Prior to being used, the welds must be ground down to meet specifications. In addition, a typical water tank in use must be repainted at least every 20 to 30 years and the welds may need to be repaired or reground. For such used tanks, it is typical that at a portion of the tank weld seams will require rewelding and grinding.
A typical 1 MG tank can be in excess of 40-48 feet tall and 60-160 feet in diameter. These tanks can include a variety of surface obstacles, high-profile welds, and complex curves, all of which can make the grinding and finishing operations difficult. When refinishing a tank, owners experience two significant costs: (1) downtime for water tank and (2) the cost of the welders or refinishers. It is, therefore, beneficial to accomplish the welding or refinishing quickly.
The majority of steel water tanks today are refinished using manual manpower to grind the welds and perform the other finishing operations. The attendant is required to hold a finishing apparatus such as a grinder, sander, polisher, or the like against the vessel. Surfaces requiring finishing can include vertical walls, horizontal floors, overhead ceilings, or a variety of curved and complex geometries. The finishing apparatuses can be heavy and cumbersome, and the need to stand and walk while holding them can be awkward and exhausting. Additionally, attendants are often required to be supported by scaffolding, ladders, booms, or the like, resulting in attendants operating equipment in awkward, uncomfortable and/or unsafe positions. This awkward and tiring method of finishing the surface can result in inconsistencies in the quality of the finishing; in particular mistakes are more likely to occur as the attendant tires.
This manual method is also very time consuming and costly, as a typical tank, hundreds, if not thousands, of man-hours. In addition, as the interior temperature can rise to 130 degrees Fahrenheit when grinding, the safety of workers becomes a crucial priority, particularly in the warmer summer months.
Consequently there is a need in the industry for an improved automated device and method for finishing such surfaces without frequent interruptions and without the use of heavy, awkward, hand-held finishing apparatuses. A moveable finishing assembly which is capable of finishing such surfaces and which does not require manual manpower would save time and the costs of labor and materials. It would also lessen the workers exposure to falls by reducing the amount of time spent on scaffolds and/or other climbing equipment.
It is an object of this invention to obviate the above-described problems.
It is another object of this invention to provide a device and method for inspecting surfaces.
It is another object of this invention to provide a device and method for finishing surfaces.
It is another object of this invention to provide a device and method for finishing surfaces and for recording the surface conditions before and after finishing the surfaces.
It is another object of this invention to provide a device and method for inspecting and/or finishing curved and/or difficult to reach surfaces.
It is another object of this invention to provide a device for inspecting and/or finishing surfaces that can move remotely along the surface.
It is another object of this invention to provide a device that can move along the surface and which can move over or avoid obstacles provided on or proximate the surface.
It is another object of this invention to provide a device and method for inspecting and/or finishing surfaces which is automated and can be used in various large scale containers.
It is another object of this invention to provide a device and method for inspecting and/or finishing surface in which the device inspects the surface, finishes the surface and then reinspects the surface.
It is another object of this invention to provide an intelligent device and method for inspecting and/or finishing surfaces in which the intelligent device senses the surface, compares the sensed surface to a predetermined profile, and finishes the surface if required.
It is another object of this invention to provide a device and method for inspecting and/or finishing surfaces using cameras, optics, acoustics, direct contact or other means to survey the surface, compare the surveyed surface to a preprogrammed profile, and work on the surface to replicate the preprogrammed profile.
It is another object of this invention to provide a device which can be used with a variety of interchangeable finishing apparatuses.
According to an embodiment, a device for finishing a surface of a work piece is disclosed. The device includes a finishing apparatus which cooperates with the surface of the work piece. A mounting member is provided which cooperates with the surface of the work piece to removably mount the device to the surface of the work piece. At least one support member extends between the mounting member and the finishing apparatus. The finishing apparatus is moveable relative to the mounting member to allow the finishing apparatus to perform a finishing operation on the surface of the work piece.
According to an embodiment, a device for finishing a surface of a work piece is disclosed. The device includes a finishing apparatus which cooperates with the surface of the work piece. A first mounting member cooperates with the surface of the work piece to removably mount the device to the surface of the work piece. At least one support member extends between the first mounting member and the finishing apparatus. Sensors analyze the surface to determine where irregularities occur. A control unit to move and/or position the device at appropriate areas on the surface of the work piece and to record the surface conditions.
According to an embodiment, a method of finishing a surface of a work piece is disclosed. The method comprising: moving a device with a movable mounting member and a finishing apparatus into position proximate an obstacle; extending support members of the device with a second mounting member attached thereto over the obstacle while maintaining the movable mounting member in contact with the surface; adjusting the second mounting member to allow second mounting member to be placed in contact with the surface of the work piece; removably mounting the second mounting member to the surface; releasing the movable mounting member from the surface; retracting the support members toward the second mounting member, thereby moving the movable mounting member over the obstacle; removably mounting the movable mounting member on the surface; releasing the second mounting member from the surface; and engaging the finishing apparatus to finish the surface.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Referring now to the drawings in detail, wherein like numerals indicate the same elements throughout the views,
In the exemplary embodiment of
In the exemplary embodiment shown in
Movably attached to the second support members 16 of the frame 12 is a tooling support platform 22. In the exemplary embodiment shown, the tooling support platform 22 supports a grinder and the various motors required for operation. However, as previously referenced, the tooling support platform 22 may support various finishing apparatuses which can perform, sanding, brushing, polishing, buffing or other similar functions.
In the exemplary embodiment shown, a grinder 24, having a grinder housing 26 (which may house a motor and the like) and a wheel 28, is shown supported by the support platform 22. While the term platform is used, it is important to understand that the platform may be a physical piece of material or may simply refer to the area in which the grinder 24 and other components, described below, are provided and in which they cooperate.
Provided proximate the platform 22 is a track travel or drive motor 30. Gears of the track travel motor 30 cooperate with a track 31 of a respective second support member 16 to allow the platform 22 and the grinder 24 to be moved in a direction parallel to the longitudinal axis of the second support member 16 when the motor 30 is engaged. In so doing, the grinder 24 is able to move in the directions of arrows A. The movement of the platform 22 is limited to the space provided between the third support members 18, as best shown in
The grinder 24 or other finishing apparatus must align with the area of the surface to be finished. In this regard, the platform 22 is illustrated as further comprising means for adjusting the grinder 24 in the direction indicated by arrow B. The platform 22 or grinder 24 is connected to a lateral movement mechanism, such as, but not limited to, a screw drive which is connected to a motor 34. As the screw drive 32 is activated, connectors 35 which are connected to the grinder 24 or the platform 22 are caused to move in the known manner. This allows the grinder 24 and/or the platform 22 to move in the lateral direction indicated by arrow B.
The grinder 24 is also able to be move in a rotational manner as indicated by arrow C. A slewing motor 36 with a slewing bearing cooperates with the housing 26 of the grinder 24 to move the grinder 24 in the direction of arrow C.
Vertical adjustments, in the direction of arrow D, of the grinder 24 relative to the frame 12 can be provided a raise and lower mechanism. As best shown in
Connected either directly or indirectly to the grinder 24, the platform 22 and other components of the finishing device 10 is a control unit (not shown). The control unit can control various functions including, but not limited to, the speed of the finishing device. The speed at which the finishing device moves along the surface of the work piece can be modified to accommodate a variety of finishing applications and environments. Sensors and the like may also be provided in communication with the control unit. By gathering and processing information provided by the sensors, the control unit can properly guide the device 10. In addition, the control unit can map the surface of the work piece, identifying areas which require additional work or which cannot be repaired with the device 10.
Before the finishing procedure, which in this exemplary embodiment is smoothing of a seam weld through grinding, can be started, the finishing apparatus or device 10 must be generally positioned in the area to be finished. Sensors 68 may be provided on the device 10 to facilitate the placement of the device 10. The positioning of the sensors may vary depending upon the type of sensors used.
Including the sensors allows the device to be an intelligent, automated device, which does not require operators or technicians to be positioned in the work piece or container. As the device 10 and sensors 68 are moved over the surface, the sensors 68 analyze the surface to determine where irregularities occur. The information is sent to the assembly control unit. The control unit uses the sent information to position the device 10 to an appropriate area on the surface of the work piece. The sensors could use, but not be limited to, cameras, optics, acoustics or direct contact to measure or survey the surface.
Once the surface is surveyed, the surveyed surface can be compared a predetermined, preprogrammed profile or condition. If the control unit determines that work must be performed on the surface to place the surface in conformity with the predetermined profile or condition, the control unit then engages the grinder 24 or other finishing apparatus to work on the surface to place the surface in conformity with the profile or condition.
In the exemplary embodiment shown, after the device 10 is generally positioned, the wheel 28 or other working head may be adjusted in the directions of arrows A, B, C and D, as was previously described.
After the finishing assembly 10 is in place and the abrasive surface of the wheel 28 of the device 10 is properly aligned with the area to be finished, the finishing process, in this case, grinding, can be started.
Once the appropriate work has been performed, the sensors 68 then re-survey or re-sense the surface to check that the desired profile or condition exists.
An attendant can control the speed and positioning at which the finishing device 10 travels along the area to be finished through means of the assembly control unit. Alternatively, the speed and positioning may be either manually or automatically controlled to provide appropriate results. In either case, the device 10 may have sensors to sense various parameters and send the relevant information back to the attendant or controller, thereby facilitating optimum grinding or finishing. After the grinding or other finishing is completed, the device 10 will be removed.
Referring to
The finishing device 110 has a frame 112 which has a first support member 114, a second support member 116 and a third support member 118. The first support member 114 is connected to and extends from second support member 116. The first support member 114 extends from proximate an end of the second support member 116 to a mounting/transport/crawler member 120, as will be more fully described. The third support member 118 extends from proximate an opposite end of the second support member 116. The third support member 118 has a grinder 124 or other finishing apparatus proximate one end and a second mounting member or mounting foot 150 proximate opposite end, as will be more fully described.
In the embodiment shown in
In the embodiment shown one crawler member 120 is shown, however, more than one crawler member 120 can be used without departing from the scope of the invention. The crawler members 120 have electro-magnetic properties which cooperate with the surface of a work piece on which the device 110 is to work. Tracks 152 can be made of any suitable material, but are preferably made from a high energy magnetic material to assisting device 110 in supporting itself magnetically on the surface of a ferromagnetic work piece. In this embodiment, the magnetic tracks 152 magnetically engage the surface, thereby maintaining the device 110 is position relative to the surface. In other embodiments, the tracks 152 may, but are not limited to, use a vacuum or other means to maintain the device 110 in position. If non-magnetic tracks 152 are used, the tracks 152 can be made of any suitable material, but are preferably a lightweight material, such as polyurethane. Depending upon the composition of the surface on which the device 110 is to be used, magnetics, vacuum, other means or a combination thereof may be used with the movable tracks 152 to allow the movable tracks 152 and the device 110 to be maintained proximate the surface while still allow the relative movement of the tracks 152 (including, but not limited to, by means of crawling, walking, sliding or other known methods of movement) and the device 10.
Each of the crawler members 120 operate in a known manner to allow the device to move relative to the surface of the work piece. For example, each crawler member 120 may have drive module which houses a gear train for driving crawler members 120. Each gear train may include a plurality of gears corresponding to and in rotational connection with crawler members 120. The gear trains may be in rotatable connection with gears through an interlocking mesh of teeth radially displaced on both the gear train and the gears.
The first support member 114 extends from and is movably connected to the crawler member 120. As shown in
In addition, the first support member 114 is mounted to the crawler member 120 by means of a second movable member 160 which is operated by a crawler servo motor. This allows the member 160 and the first support member 114 to move in the direction as indicated by arrow K.
The second support member 116 is mounted to the first support member 114 by means of a third movable member 162 which is operated by an arm servo motor. This allows the member 162 and the second support member 116 to move in the direction as indicated by arrow L relative to the first support member 114.
The third support member 118 is mounted to the second support member 116 by means of a fourth movable member 164 which is operated by a foot servo motor. This allows the member 164 and the third support member 118 to move in the direction as indicated by arrow M relative to the second support member 116.
As previously stated, the third support member 118 has a grinder 124 or other finishing apparatus provided at one end and a mounting foot 150 provided at the opposite end. The third support member 118 extends from and is movably connected to the mounting foot 150. As shown in
The mounting foot 150 is an electro-magnetic member which, when positioned proximate the surface of the work piece cooperates with the surface of a work piece. Mounting foot 150 can be made of any suitable material, but are preferably made from a high energy magnetic material to assist device 110 in supporting itself magnetically on the surface of a ferromagnetic work piece. In other embodiments, the mounting foot 150 may, but is not limited to, use a vacuum or other means to maintain the mounting foot 150 and device 110 in position. If a non-magnetic mounting foot is used, the mounting foot 150 can be made of any suitable material, but is preferably a lightweight material, such as polyurethane. Depending upon the composition of the surface on which the device 110 is to be used, magnetics, vacuum, other means or a combination thereof may be used with the mounting foot 150 to allow the mounting foot 150 and the device 110 to be maintained proximate the surface.
Connected either directly or indirectly to the finishing device 110 is a control unit (not shown). The speed at which the finishing device moves along the surface of the work piece and the speed at which the finishing apparatus cooperates with the surface can be modified to accommodate a variety of finishing applications and environments.
Before the finishing procedure, which in this exemplary embodiment is smoothing of a seam weld through grinding, can be started, the finishing apparatus or device 110 must be moved into position using the tracks 152 to generally position the device 110 in the area to be finished. Sensors 168 may be provide on the device 110 to facilitate the placement of the device 110. The positioning of the sensors may vary depending upon the type of sensors used.
Including the sensors allows the device to be an intelligent, automated device, which does not require operators or technicians to be positioned in the work piece or container. As the device 110 and sensors 168 are moved over the surface, the sensors 168 analyze the surface to determine where irregularities occur. The information is sent to the assembly control unit. The control unit uses the sent information to position the device 110 to an appropriate area on the surface of the work piece. The sensors could use, but not be limited to, cameras, optics, acoustics or direct contact to measure or survey the surface.
Once the surface is surveyed, the surveyed surface can be compared a predetermined, preprogrammed profile or condition. If the control unit determines that work must be performed on the surface to place the surface in conformity with the predetermined profile or condition, the control unit then engages the grinder 124 or other finishing apparatus to work on the surface to place the surface in conformity with the profile or condition.
In the exemplary embodiment shown, after the device 110 is generally positioned, the wheel 128 or other working head may be adjusted in the various directions through the movement of the various components in the directions of arrows J, K, L, M and N, as was previously described.
After the finishing assembly 110 is in place and the abrasive surface of the wheel 128 of the device 110 is properly aligned with the area to be finished O, the finishing process, in this case, grinding, can be started.
Once the appropriate work has been performed, the sensors 168 then re-survey or re-sense the surface to check that the desired profile or condition exists.
An attendant can control the speed and positioning at which the finishing device 110 travels along the area to be finished through means of the assembly control unit. Alternatively, the speed and positioning may be either manually or automatically controlled to provide appropriate results. In either case, the device 110 may have sensors to sense various parameters and send the relevant information back to the attendant or controller, thereby facilitating optimum grinding or finishing. After the grinding or other finishing is completed, the device 110 will be removed.
Referring to
If only a small area of the surface proximate the obstacle 170, and on the side of the obstacle which is removed from the device 110, must be refinished, the operation of the device 110 can be similar to that described above. The device 110 is moved into position using the tracks 152 to generally position the device 110 proximate the obstacle 170 and proximate the area to be finished.
After the device 110 is generally positioned, the wheel 128 or other working head may be extended over the obstacle 170 and adjusted in the various directions through the movement of the various components in the directions of arrows J, K, L, M and N, as was previously described.
After the device 110 is in place and the abrasive surface of the wheel 128 or other working head of the device 110 is properly extended over the obstacle and properly aligned with the area to be finished, the finishing process, in this case grinding, can be started.
Referring to
The device 110 is moved into position using the tracks 152 to generally position the device 110, with the movable mounting member or crawler 120 and the finishing apparatus 124, proximate the obstacle 170. With the movable mounting member 120 maintained in position, the support members and the second mounting member or mounting foot 150 is then extended over the obstacle 170 and adjusted in the various directions through the movement of the various components in the directions of arrows J, K, L, M and N, as was previously described. This allows the mounting foot 150 to be secured or removably mounted in contact with the surface of the work piece. As previously described, in the exemplary embodiment shown, the mounting foot 150 is placed in magnetic engagement with the surface. In other embodiments, the mounting foot 150 may placed in engagement with the surface by means of a vacuum or the like. When so positioned, the mounting foot 150 is securely maintained in position relative to the surface.
With the mounting foot 150 properly secured, the magnet or other holding means of the track 152 of the movable mounting member 120 are released, allowing the track to be lifted from the surface. The track 152, crawler member 120 and support members are then retracted over the obstacle 170 toward the mounting foot 150 through the movement of the various components in the directions of arrows J, K, L, M and N.
With the crawler member 120 moved across the obstacle 170, the track 152 is moved into engagement with the surface. Once the track 152 is secured or movably mounted, the mounting foot 150 is released and the device 110 is operated as previously described.
The device and method of inspecting and or finishing a surface of a vessel, container or work surface, as described with reference to the exemplary embodiments, allows for automated inspection and/or finishing without the need for workers to be positioned in the container or proximate the work surface. In addition, the automated device and method allows for the inspection and/or finishing of such surfaces without frequent interruptions and without the use of heavy, awkward, hand-held finishing apparatuses, thereby eliminating the need for manual manpower resulting in a savings of time and the costs of labor and materials. The automated device and method also lessens the workers exposure to falls by reducing the amount of time spent on scaffolds and spiders.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
This application claims priority to U.S. Provisional Application No. 61/789,364 filed Mar. 15, 2013, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61789364 | Mar 2013 | US |
