Size Reduction Machine

Category: Dismantlement > Mechanical Cutting Equipment > Mobile Shears
Reference # : OST No 2395 , DOE/EM-0529 Model No : SRM

The SRM is a segmentation (mechanical cutting) tool used for pipe and component cutting. It is a hydraulic assist device that allows the weight of the shear to be borne by the machine. This allows an operator to place the shear head at a location to be cut with minimal physical effort. Gross movement between cuts and for initial alignment of the SRM is manually controlled by two operators who manually move the base unit.The SRM is split into four design areas; base unit, control box, moveable arm, and shear head. The base unit, or body of the device is 34.75" wide (without outriggers) by 48" long by 72" high, consisting of a triangular housing that holds the hydraulics, power, and control units. The housing also serves as the support structure for the shear arm. Mounted on casters, the base unit can be moved easily on smooth level surfaces and is counter weighted to offset the tipping moment when the main arm is extended fully in the horizontal position. In addition, extendable manual outrigger legs are attached to the outer housing to assist in stability.The inner portion of the base unit contains the hydraulic pumps, servos, and reservoirs needed to control and maintain the hydraulic shear and arm. The hydraulic system comprises a high pressure, 5500 psi, 1.2 gpm, Enerpac pump, a valve pack and a reservoir tank for operating the shear. An additional pump system operating at 2200 psi, 3.0 gpm controls the support arm and head, using a separate reservoir feed tank. The control unit utilizes a bank of proportional valves, to allow feathering of the hydraulic components. An electronic control valve for each motor and actuator are mounted with the pumps. Other electrical and electronic control components are located in this space. There is additional space for future expansion within the base unit.A tethered control box with a 20 foot cable on a rolling table, controls the unit and can be positioned for complete visual access to the cutting location. The control box can also be mounted on the operator by using a harness with waist and shoulder straps. The layout of the control box consists of three joysticks, an on-off switch, a retract/shear button, a retract/clamp gripper button. These control the various freedoms of motions of the designated mechanical component that isselected. Two motions can be utilized at the same time. The joysticks are potentiometers that control the proportional valves mounted with the hydraulic controls in the base unit. Movement of all devices is under positive control - a controlling button, joystick or switch must be held by the operator or the action stops. A single on/off button on the control box controls all power functions of the SRM. The relative position of moving parts is maintained if power is shut off or lost. A standby switch allows the cooling fan to run while the hydraulic pumps re-circulate at no pressure. The hydraulic extension arm is attached to the top of the base unit through a pivot. The 3.5" bore, 36" long hydraulic cylinder rotates about this point. The arm can extend 36" horizontally using rollers, rails and a hidden second hydraulic cylinder with a 2" bore and 36" stroke. The last degree of movement for the arm is based on a 2" bore, 6" long extension cylinder mounted on the end of the sliding arm just behind the head unit. Because of the three motions of the arm, anything from 1 foot below the floor level to 15 feet above the floor is accessible to the unit.The shear head is adapted from a Champion Rescue Tool shear head. It is capable of cutting through 3"x 3" stainless steel angle iron, 4" schedule 40 stainless steel pipe, and 3 «" x 3 «" stainless steel flat bar. The shear is mounted in a tool mount that has three axes of motion. The first motion is affected through a rotary actuator that allows the shear head to rotate 360 degrees around the X-axis. The motion around the Z-axis comes from a second rotary actuator. The final motion is through the Y-axis chain-drive, rotary actuator. Within reason, the freedom of motion for the shear should provide an adequate level of positioning to minimize movement of the base unit, except for gross lineup in the perpendicular direction. Also mounted to the shear head is a gripper, which assists in holding the item being cut. The cut piece must still be rigged to lower it to the ground if cutting in the overhead position.Dimensions of Tech Model (LxWxH):Weight of Tech Model (lb.): 1400

Benefits

· Similar speed in cuts/ hour to the baseline · Less fatiguing to operators · Safer, removes operators from harm’s way · Cuts larger items faster · Easier to use when dressed out in protective clothing

Limitations

-SRM could not cut certain configurations due to width of shear and gripper combination. - Motorizing the base unit would reduce overall setup time and cutting time. - A laser range pointer with a homing device on the shear head would assist in rapid placement and final maneuvering of the shear head. - Use of flexible or expanding boots around telescoping cylinders and joints would simplify decontamination of the unit. - An onboard computer would make it possible for the unit to automatically cycle through repetitive motions. - A larger shear (8-inch) could easily be accommodated on the SRM in place of the current 6- inch size, increasing the cutting capacity.

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