U.S. patent application number 11/716108 was filed with the patent office on 2007-07-26 for boom with mast assembly.
This patent application is currently assigned to Shook Mobile Technology, L.P.. Invention is credited to Eric E. Lowman.
Application Number | 20070172032 11/716108 |
Document ID | / |
Family ID | 32682501 |
Filed Date | 2007-07-26 |
United States Patent
Application |
20070172032 |
Kind Code |
A1 |
Lowman; Eric E. |
July 26, 2007 |
Boom with mast assembly
Abstract
A torsion- and bending resistant boom formed of beams running
the length of the structure, a set of pierced, transverse flanges
arrayed along, and substantially perpendicular to, the length of
the structure, a continuous longitudinal member running the length
of the structure, piercing the flanges, and several further
longitudinal members, outward of the first member. The longitudinal
members are welded to the flanges. An elevatable mast assembly
raises and lowers the boom, and has a mast and guides formed of
hollow tubes, and rollers between the guides and the mast, the
rollers transferring torque loading to the guides.
Inventors: |
Lowman; Eric E.; (Cibolo,
TX) |
Correspondence
Address: |
AKIN, GUMP, STRAUSS, HAUER & FELD, L.L.P.
P.O. BOX 12870
SAN ANTONIO
TX
78212
US
|
Assignee: |
Shook Mobile Technology,
L.P.
Schertz
TX
78154
|
Family ID: |
32682501 |
Appl. No.: |
11/716108 |
Filed: |
March 9, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10861978 |
Jun 4, 2004 |
7207713 |
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11716108 |
Mar 9, 2007 |
|
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09451830 |
Nov 30, 1999 |
6763635 |
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10861978 |
Jun 4, 2004 |
|
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Current U.S.
Class: |
378/198 |
Current CPC
Class: |
G01V 5/0016 20130101;
B60P 1/5433 20130101; B66C 23/18 20130101; B66C 17/06 20130101;
B66F 11/046 20130101 |
Class at
Publication: |
378/198 |
International
Class: |
H05G 1/02 20060101
H05G001/02 |
Claims
1-49. (canceled)
50. An elevatable mast assembly for lifting a load above a
supporting structure, comprising: a mast having an elevation axis;
a guide assembly having a plurality of guiding elements, wherein
said guiding elements are fixed to the supporting structure; and a
plurality of roller assembly sets, wherein said sets inhibit
translation of said mast relative to said guiding elements but
permit such translation along the elevation axis.
51. The elevatable mast assembly of claim 50, the mast assembly
comprising a plurality of joined parallel mast sections, and said
mast sections and said guiding elements comprising metal
tubing.
52. The elevatable mast assembly of claim 50, wherein said guiding
elements are spaced radially outward of the mast, and said guiding
elements and said mast are aligned to said translation axis.
53. The elevatable mast assembly of claim 50, each of said roller
assembly sets comprising a plurality of roller assemblies, each
said assembly having at least one roller and a mount; wherein the
mounts of a first set of roller assemblies are fixed to said
guiding elements and the mounts of a second set of roller
assemblies are fixed to said mast.
54. The elevatable mast assembly of claim 53, further compromising
a direction of elevation, wherein said first set is in the
direction of elevation from said second set.
55. The elevatable mast assembly of claim 53, wherein said first
set is further along said elevation axis than said second set.
56. The elevatable mast assembly of claim 50, each of said roller
assembly sets comprising a plurality of rollers, wherein the
rollers of at least one set are in rolling contact with said mast
and the rollers of at least one other set are in rolling contact
with said guiding elements.
57. The elevatable mast assembly of claim 56, wherein said rollers
in rolling contact with said mast are above said rollers in rolling
contact with said guiding elements.
58. The elevatable mast assembly of claim 50, said mast comprising
at least four parallel mast sections, each of said mast sections
comprising a hollow metal tube; said guide assembly comprising at
least four guiding elements, each of said guiding elements
comprising a hollow metal tube; and a screw jack elevation system;
wherein at least one guiding element is located radially outwardly
of each of said mast sections from said elevation axis.
59. In a mobile transport for emitting penetrating radiation, for
scanning targets with said radiation and for sensing said radiation
using sensors, the transport for movement along a direction of
travel, a mast system, comprising: a mast having an translation
axis; a guide assembly having a plurality of guiding elements,
wherein said guiding elements are fixed to the supporting
structure; and a plurality of roller assembly sets, wherein said
sets guide translation of said mast along the translation axis.
60. The mast system of claim 59, said mast comprising a plurality
of parallel mast sections, each of said mast sections comprising a
hollow metal tube, said guide assembly comprising a plurality of
guiding elements, each of said guiding elements comprising a hollow
metal tube, wherein at least one guiding element is located
radially outwardly of each of said mast sections from said
translation axis.
61. The mast system of claim 59, each of said roller assembly sets
comprising a plurality of roller assemblies, each said assemblies
having at least one roller and a mount; and the mast assembly
further compromising a direction of elevation; wherein the mounts
of a first set of roller assemblies are fixed to said guiding
elements the mounts of a second set of roller assemblies are fixed
to said mast, and said first set is in the direction of elevation
from said second set.
62. The mast system assembly of claim 59, comprising at least a
first and second roller assembly set, each of said roller assembly
sets comprising a plurality of rollers; wherein the rollers of the
first set are in rolling contact with said mast, the rollers of the
second set are in rolling contact with said guiding elements, and
said rollers in rolling contact with said mast are above said
rollers in rolling contact with said guiding elements.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to booms and mast structures
for supporting a load, and to those supporting torque-inducing
loads. In particular, if relates to a boom structure that may be
rotated, and a mast structure that may be elevated. More
particularly, it relates to a boom and mast structure mounted on a
mobile platform for deployment of a system for inspection of
vehicles or containers.
[0003] A boom used to support a load at a distance from a vertical
support must resist deformation resulting from the downward forces
applied thereto by that load, and the torque created thereby. In
addition, where that boom and load may be subject to acceleration
resulting from translation or rotation, or other application of
forces, in other than the vertical direction, the boom must also
resist torsion along its long axis. The necessity of resisting
torsion will be increased by a further load in the form of a
vertical portion extending downwardly from its far end, which acts
to intensify torsional effects created by movement out of the
vertical.
[0004] A mobile transport may have a mast mounted thereon, and a
boom mounted atop the mast, which is rotatable with respect to the
mast, and which has a vertical portion supported by its far end.
For use in inspection of vehicles or containers, the mobile
transport may mount a transmitter and sensors, on the boom and the
vertical portion, for inspecting vehicles or containers which pass
below and inward of the boom as the mobile transport is propelled
past those items. In this,situation, in order to increase the
accuracy of the inspection, it is particularly important to resist
torsion and bending to minimize changes in the position of the boom
relative to the transport. Further, where the mast is to be raised
of lowered along a vertical axis, the system used to do so must
also guide that movement, and resist torque created by the load of
the boom and its load.
[0005] 2. Background Art
[0006] A structure supporting a load at a distance is subject to
both bending and torsional effects, particularly when a further
perpendicular structure is supported at a distance from the point
of support. The use of metal tubes or beams for constructing such
structures is known, as is use of C-channel beams to resist torsion
or bending. However, such structures, if relatively long, are
subject to buckling if not reinforced, and may not be sufficient to
resist higher bending and torsion loads. Construction, and
reinforcement of, such a structure installed upon a mobile platform
must also address weight concerns related to vehicle weight and
stability. Further, such structures must also resist movement of
the structure relative to the point of support. Previous devices
disclosed in patents include the following:
[0007] U.S. Pat. No. 5,152,659 to Waka discloses a boom assembly
having an inflection point therein that utilizes two opposing upper
and lower welded C-channels to form a box structure. The booms are
used to form the arms supporting the bucket of a bulldozer. Waka
does not address the use of tubes, or other reinforcements.
[0008] U.S. Pat. No. 5,568,829 to Crawford et al. discloses a boom
for a sliding boom delimber, for use in the logging industry, the
boom utilizing a pre-stressed I-beam to enclose and support power
and control cables to the delimbing apparatus attached at its end.
Crawford et al. do not address the use of tubes, or other
reinforcements.
[0009] U.S. Pat. No. 5,692,028 to Geus et al. discloses a x-ray
examining apparatus mounted on a mobile vehicle, including a
support structure and detectors mounted on the supporting
structure. Geus et al. do not address construction of any boom,
mast or other structure supporting the detectors, or how to
minimize movement of the support structure relative to the
vehicle.
[0010] U.S. Pat. Nos. 5,764,683 and 5,903,623 to Swift et al.
disclose a mobile device for inspection of containers, including
detectors that may be supported from a horizontal boom extending
from the mobile device. Swift et al. do not address construction of
a boom or mast supporting the detectors, or how to minimize
movement of the boom relative to the mobile device.
[0011] In addition, a mast assembly is known for raising and
lowering a load from a mobile platform; such structures often
utilize a mast formed of a hydraulic piston. A lateral load, such
as that resulting from torque applied by a boom in the present
invention, may be applied. In the absence of a separate guiding
system, lateral loading would be transmitted through the hydraulic
seals (often O-rings) to the cylinder walls, which may unduly
compress those seals, and cause failure of these seals. Because a
hydraulic lift system can fail, permitting the mast to drop, such
systems may include a latching mechanism, to support the mast and
load in an elevated position. However, this adds weight and cost.
Such structures do not address the torque and load concerns of the
described inspection system.
[0012] It can be seen that the foregoing do not meet all of the
needs for a boom and mast structure that is rigid and
torsion-resistant, and resistant to buckling and undesirable
movement.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention provides a highly rigid,
torsion-resistant, and buckle-resistant boom design, which may
include a vertical portion, providing stable support for the
supported load. This invention provides a horizontal boom section,
and in a preferred embodiment includes a vertical boom section
depending downwardly from the distal end of the horizontal boom
section. In another preferred embodiment, the proximal end of the
horizontal boom section is preferably mounted to a vertical
support, such as an elevatable mast, permitting vertical movement
of the boom/mast structure, and rotation of the boom structure.
[0014] In preferred mode of operation, a series of vehicles,
typically tractor-trailer rigs, or cargo containers, are placed in
a line parallel to the intended direction of travel of the mobile
inspection unit which incorporates a preferred embodiment of the
invention. The unit is propelled forward so that a scanning zone of
an inspection system passes through each of the rigs or containers
in succession. The data gained from these scans is viewed and
interpreted by an operator in the mobile transport. Accurate
alignment and minimized relative movement between the radiation
source and the sensors is critical. Because the sensors are mounted
upon the boom sections, it is important to increase the torsional
and bending resistance, and the resistance to buckling, of those
sections, particularly the horizontal boom section. Torsion forces
may act upon the boom in a number of ways. For instance, forward
acceleration of the mobile inspection unit, and the resistance to
motion of the boom structure, will result in inertia opposing that
acceleration. This effect will be increased where that resistance
is placed at a distance from the source of support, such as the
vertical boom structure, supported at the end of the horizontal
boom structure. Other sources of torsional effects include wind
resistance and accidental obstruction of the boom structure.
Similarly, bending forces are present resulting from the weight of
the sensors and the boom's own weight.
[0015] In a preferred embodiment, a horizontal boom section
includes a continuous inner tube, or rod, which runs the length of
the horizontal boom section. This inner tube penetrates several
flanges arrayed along the length of the boom section. The flanges
are preferably perpendicular to the inner tube, and are joined to
it at the penetration. Individual, discontinuous, outer tube
segments are placed outwardly of the inner tube, preferably
concentrically, between and abutting, but not penetrating, the
flanges. The outer tube segments are joined at their ends to the
flanges' faces, preferably in grooves sized to those segments.
Inward-facing C-channel beams, running the length of the horizontal
boom section, are joined on their inward faces to the flanges' side
edges, preferably congruently. Tensioning cables provide upward
support for the ends of the structure, and permit a torque to be
applied to straighten the structure.
[0016] Preferably, the boom further includes a vertical boom
section, including a set of continuous tubes, or rods, which run
the height of the vertical boom section, and penetrate several
flanges arrayed along its height. The several flanges are
substantially perpendicular to the vertical, and preferably
congruent to inward-facing C-channel sections. The C-channel
sections run the height of the vertical boom section, and are
joined to the flanges. In a particularly preferred embodiment, a
joint is provided roughly in the middle of the vertical boom
section, permitting the lower segment to be folded upwardly against
the upper segment, reducing the overall length of the vertical boom
section for ease of stowage.
[0017] In a preferred embodiment, in order to facilitate elevation
and rotation of the boom relative to a mobile transport, a
mast-head and mast assembly are provided. The horizontal boom
section, to which the vertical boom section is preferably mounted,
is mounted to a mast-head, which is itself mounted to a mast
assembly. The mast assembly is mounted to the chassis of the mobile
transport. A mast assembly includes a mast guide and an elevation
system to elevate the mast and the boom structure supported
thereby. The mast-head is mounted to the top of the mast assembly,
facilitating joinder of the horizontal boom section to the mast.
The mast-head includes a rotation drive for rotating the boom
structure. A counterweight structure may also be mounted to the
mast-head, opposing the torque created by the weight of the boom
structure.
[0018] The mast is preferably rigid, resistant to torque, and
transmits out-of-vertical forces to the chassis without adversely
affecting operation of the elevation system. In a preferred
embodiment, a composite mast, formed of a two-by-two square
grouping of hollow square-section tubes provides such rigidity and
strength. The mast assembly further preferably includes a guide for
the mast, which includes four similar hollow square-section tubes
fixed to the chassis outwardly of the corners of the mast, and
rollers between the mast corners and the inner corners of the
guide. Preferably, several sets of rollers are positioned at
varying heights along the mast. The rollers permit translation of
the mast relative to the guide, which is fixed to the chassis, but
transmit to that chassis the forces out of the vertical, created by
torque of the weight of a boom or load. The elevation system also
preferably includes a screw and a screw jack, which require little
power for operation and are very reliable. This system has
advantages over alternatives, such as a hydraulic lift for a
similar mast, or a mast formed of a hydraulic piston. The weight
and cost of an additional latching system are avoided by using the
screw jack system, which does not depend upon a hydraulic power
source for lift, and can maintain position without power input. The
present invention also avoids compression and failure of hydraulic
seals by omitting them and transmitting any lateral loads via
rollers, which are designed to transmit this load to the guide.
[0019] In a further preferred embodiment, loads supported by the
boom sections include their own weight and sensors for detecting
transmitted radiation for inspecting vehicles and containers inward
of and below the boom. Various types of sensors may be used, such
as transmission, backscafter, sidescatter and forward scatter
detectors. In this preferred embodiment, the boom structure is
mounted on a mast, itself mounted to the chassis of a mobile
transport. The boom sections may be rotated relative to the mast,
to a position in which they extend roughly perpendicular to the
transport's direction of forward travel. The bottom end of the
vertical boom section preferably extends proximate the ground
surface. In this position, the horizontal and vertical boom
sections form, with the adjacent side of the transport, an
essentially planar rectangular scanning zone. A radiation source,
typically an X-ray emitter, is mounted on the mobile transport,
along with the necessary support equipment, power source and
operator. The X-ray device emits penetrating radiation into the
scanning zone and toward sensors mounted upon the inward face of
the vertical boom section, and upon the lower face of the
horizontal boom section. The X-ray device may provide coverage of
the scanning zone by repeatedly sweeping a narrowly focussed beam
aligned to the plane, or by other techniques permitting radiation
transmission covering a planar area. If the radiation would tend to
penetrate the sensor, or the boom's structural material, additional
absorptive material, such as lead, may be employed to do so.
[0020] The further scope of the invention will become apparent upon
the review of the detailed description of the preferred
embodiments. It should however be understood that these
descriptions do not limit the scope of the invention and are given
as examples only, and that various changes and modifications which
are fully within the scope of the present invention will become
apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The present invention is more easily understood with
reference to the drawings, in which:
[0022] FIG. 1A is a partial cutaway top view of the mobile
inspection unit depicting the boom assembly in the deployed
position.
[0023] FIG. 1B is a partial cutaway elevation of the mobile
inspection unit depicting the boom assembly in the deployed
position.
[0024] FIG. 1C depicts partial section A-A of the mobile inspection
unit.
[0025] FIG. 1D is an end view of the mobile inspection unit
depicting detail of the boom assembly in the deployed position.
[0026] FIG. 2A is a top view of the mobile inspection unit
depicting the boom assembly in the stowed position.
[0027] FIG. 2B is a partial cutaway elevation of the mobile
inspection unit depicting the boom assembly in the stowed
position.
[0028] FIG. 3 depicts section B-B of the vertical boom section.
[0029] FIG. 4 depicts section C-C of the horizontal boom
section.
[0030] FIG. 5A is an elevation of a horizontal boom section
flange.
[0031] FIG. 5B is an edge view of a horizontal boom section
flange.
[0032] FIG. 6A depicts section D-D of the instrument boom.
[0033] FIG. 6B depicts partial section E-E of the horizontal boom
section.
[0034] FIG. 6C is a partial cutaway elevation of the mast-head.
[0035] FIG. 6D depicts section F-F of the mast-head.
[0036] FIG. 7A is a top view of a vertical boom section flange.
[0037] FIG. 7B is an edge view of a vertical boom section
flange.
[0038] FIG. 8A is an elevation of the joint between horizontal and
vertical boom sections.
[0039] FIG. 8B is an end view of the joint between horizontal and
vertical boom sections.
[0040] FIG. 9 depicts section G-G of the vertical boom section.
[0041] FIG. 10 is a partial cutaway of detail of the mast assembly
and rotation system.
[0042] FIG. 11 is a partial cutaway top view of the rotation
system.
[0043] FIG. 12 depicts section H-H of the mast assembly.
[0044] FIG. 13 is an elevation of the terminal flange.
[0045] FIG. 14A is a plan view of the mast-head extension, with the
cover panel removed, showing joinder to the mast-head.
[0046] FIG. 14B is an elevation of the mast-head extension with the
sheeting removed, showing joinder to the mast-head.
[0047] FIG. 15 depicts detail of the wire cage transmission.
[0048] FIG. 16 depicts detail of section I-I.
[0049] FIG. 17A is an elevation of an alternative horizontal boom
section flange.
[0050] FIG. 17B is an edge view of an alternative horizontal boom
section flange.
[0051] FIG. 17C is a partial cutaway bottom view of alternative
horizontal boom section.
[0052] FIG. 18 is an exploded view of the joint between horizontal
and vertical boom sections.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] Referring now to the accompanying figures, and in particular
to FIGS. 1A-1D, a specific preferred embodiment of the present
invention is depicted as mobile inspection unit 1 including
instrument boom 10. Instrument boom 10 includes horizontal boom
section 20, vertical boom section 22; sensor packages 24, and
associated mast assembly 12. Mast assembly 12, mounted on chassis 6
of mobile transport 2, includes mast 13, mast-head 14, mast guide
15, counter-weight 16 and turntable bearing 17.
[0054] Referring also to FIG. 2B, mobile inspection unit 1 may be
self-propelled and operated from cab 4, or may incorporate an
independent tractor (not depicted). Inspection unit 1 moves along
movement axis 5 (FIG. 1A), normally also the longitudinal axis of
the unit. Mobile inspection unit 1 includes mobile transport 2,
which will ordinarily have a conventional main drive system 3,
suitable for propelling mobile inspection unit 1 on ordinary roads
or highway systems. Drive system 3 may include such conventional
components as a diesel engine, transmission, drive shaft,
suspension components, axles, brakes and a steering system for
steering the front set of wheels 7. Mobile transport 2 further
includes chassis 6, and transport body 8. Transport body 8 is
mounted on chassis 6 in a conventional fashion, while chassis 6 is
supported by wheels 7. The number and arrangement of wheels may
vary with the load to be borne, the desired chassis size and the
use of an independent tractor.
[0055] Referring to FIG. 1A, transport body 8 comprises forward
compartment 106, and operator compartment 107, preferably separated
by wall 109. Forward compartment 106 includes cathode unit 104 and
anode unit 105, which are operably connected to radiation emitter
112 in a manner known to persons skilled in the art. Emitter 112 is
capable of emitting penetrating radiation suitable for inspection
of vehicles and containers for contraband such as illegal drugs,
weapons and the like. Emitter 112, in the preferred embodiment is
an X-ray emitter; any of several types of emitters may be employed
depending upon target composition and other design criteria. Oil
cooler 108 is preferably included, and provides cooling for cathode
and anode units 104, 105; its capacity may be determined by a
person of ordinary skill based upon the cooling needs of the
specific equipment utilized. Referring to FIGS. 1A, 1B, power is
supplied by generator 102, preferably capable of providing 100 kW
three-phase power, mounted upon the rear portion of chassis 6. A
model DCA-100 by M.Q. Power is acceptable. Cooling for transport
body 8 is provided by air conditioning units 9, preferably
three-ton models, mounted upon transport body 8.
[0056] Referring to FIGS. 1B and 1C, equipment compartment 103 is
adjacent forward compartment 106, and the exterior of transport
body 8, and houses emitter 112, beam collimator 113 and backscatter
detectors 116. Preferably, in order to mount emitter 112 close to
ground 125 to permit inspection of low portions of target 131,
subfloor 111 is used, supporting emitter 112 and collimator 113.
Subfloor 111 is preferably mounted as low as 12 inches above ground
125. Emitter 112 should be mounted in such a manner as to reduce
movement relative to instrument boom 10, and preferably in a rigid
fashion, directly or indirectly, to chassis 6. In operation,
protective doors 117 are opened to expose this equipment to
inspection target 131. Protective doors 117 may also be closed, as
in FIG. 2B, during transport or otherwise to protect the
equipment.
[0057] In FIGS. 1A-1C, emitter 112, operating with cathode and
anode units 104, 105, emits penetrating radiation aligned with the
deployed position of instrument boom 10. This penetrating radiation
preferably passes through collimator 113, which narrows this beam
in a fore and aft direction and restricts it to a roughly planar
scanning zone 114, which is directed toward sensors 24. Sensors 24
are suitable for detecting penetrating radiation emitted by emitter
112. Scanning zone extends from an angle a1, preferably below
horizontal, to angle a2, above horizontal. Preferably, scanning
zone 114 extends from about 4 degrees below the horizontal to about
74 degrees above. These values may differ depending upon the size
of target 131 and its placement relative to emitter 112, and may be
determined by a person of skill in the art.
[0058] Turning to FIGS. 1B, 1C, 10 and 12, mast guide 15, a portion
of mast assembly 12, is also located within forward compartment
106. Mast guide 15 encloses and supports mast 13, and the mast
elevation system. Mast guide 15 is mounted, preferably by welding,
to mast assembly base 21. Base 21 is mounted to mobile transport 2,
preferably to chassis 6, providing support for instrument boom 10.
Mast 13, supported by guide 15, acts as a vertical support of the
end of horizontal boom section 20. In different embodiments, an end
support, which may provide one or both of vertical support or
torque for horizontal and vertical boom sections 20, 22, may also
be provided directly by a mast-head structure, the mast itself, or
another supporting structure, known to a person of ordinary skill
in the art.
[0059] Referring to FIGS. 1C, 10 and 12, the mast elevation system
preferably includes screw jack 91, hub nut assembly 92 and screw
93. Screw jack 91 includes an electric motor and a jack, and is
mounted to assembly base 21. A 1/2 to 1 H.P. motor, and a ten-ton
load capacity jack, for transferring the input of the motor to
screw 93 were found acceptable. In a preferred embodiment, an
ACTIONJAC brand model no. 10BSJ jack is used in screw jack 91.
Screw jack 91 rotates screw 93, which acts upon hub nut assembly 92
to elevate mast 13 within mast guide 15. Hub nut assembly 92,
within which screw 93 rotates, translates screw 93's rotation to
motion along a vertical axis aligned with screw 93 and hub nut
assembly 92; preferably this vertical axis is aligned with mast
13's vertical axis. Hub nut assembly 92 incorporates multiple sets
of ball bearings transferring the load of mast 13 to screw 93, and
is advantageous over other options, such as a simple hub threaded
to screw 93, by offering lower resistance to operation, needing
less lubrication, and having a lower power requirement for the
motor for screw jack 91. Hub nut assembly 92, fixed to mast 13 via
mast baseplate 174, transmits the vertical motion to mast 13, while
screw 93 is fixed to mast elevation drive 91. Screw cutaway 95,
formed by removing interior portions of mast tubes 176, permits
rotational and translational movement of screw 93 relative to mast
13. Screw guard 87, preferably fixed within screw cutaway 95,
prevents other components, e.g. cabling, from contacting screw 93,
and either damaging that component or fouling screw 93.
[0060] In another embodiment, the mast elevation system comprises a
hydraulic piston assembly fixed to mast 13, including a hydraulic
pump, a piston acting upon mast 13, preferably upon baseplate 174,
controls and, preferably, a latching mechanism. The latching
mechanism is used to maintain elevation of mast 13 should the
hydraulic system lose pressure or otherwise fail. Failure, and
uncontrolled dropping of mast elevation, during operations, could
result in horizontal boom section 20 contacting target 131 and
significant damage to both. In this way the above screw jack system
is advantageous, in that such a latching mechanism is
unnecessary.
[0061] Remaining with FIGS. 1C, 10 and 12, operation of the mast
elevation system raises instrument boom 10, about 22 inches in a
particularly preferred embodiment, to create top clearance 129
between target 131 and sensor package 24 on horizontal boom section
20, when instrument boom 10 is in the deployed position. In the
preferred embodiment, top clearance 129 is between about six and
about eight inches, and this results in sensor package 24 being
about 168-169 inches above ground 125 when instrument boom 10 is in
fully raised position, as depicted in FIG. 1C. Ground clearance 126
between lower boom segment distal end 29a is preferably about five
inches in the deployed position. In the raised position of this
preferred embodiment, the top of instrument boom 10 is about 184
inches above ground 125, and the bottom of sensor package 24 on
horizontal boom section 20 is about 168 inches above ground 125.
Turning to FIG. 2B, in this preferred embodiment's lowered
position, the underside of mast-head 14 clears the top of transport
body 8 by about 6 inches, while sensor package 24 is about 146
inches above ground 125, and when in the stowed position, stowed
clearance 132 is about four inches above the top of transport body
8, and the top of boom 10 is no more than 162 inches above ground
125. Returning to FIG. 1C, horizontally, there is preferably at
least about 144 inches between protective doors 116, on the working
side of transport body 8, and sensor package 24 on vertical boom
section 22, which permits side clearance 128 of about 21 inches on
either side of a target 131 having a road-legal width of 102
inches.
[0062] Remaining with FIGS. 1C, 10 and 12, mast 13 comprises a
plurality of mast sections and guide rails 179. In a preferred
embodiment, the mast sections are four mast tubes 176, and in a
particularly preferred embodiment, mast tubes 176 are hollow,
squared tubes, about six inches square in section, having a wall
thickness of about 3/8 inch, and are about 96 inches in height.
Mast tubes 176 are preferably constructed of stainless steel or
another steel suitable for the predicted loading. Preferably, four
mast tubes 176 are arranged in a parallel fashion in a square
two-by-two array, and are mounted together by welding
intermittently along the exposed seams/edges between the tubes.
Mast baseplate 174 is also fixed, preferably by welding, to the
lower ends of mast tubes 176, which assists the tubes to retain
their configuration. Mast top plate 164 is similarly fixed to the
upper ends of tubes 176. Mast 13 is aligned on a translation axis,
preferably vertical, as is mast guide 15, to permit vertical
translation. Mast tubes 176 are mounted at their upper end, via
mast top plate 164, to lower plate 158 of turntable 17, in FIG. 16,
preferably by welding. Preferably, four guide rails 179 are mounted
to the outer corners of the square array of mast tubes 176, by
fixing the inner face of the rail to the exposed outer corner of
each of mast tubes 176. In one embodiment, guide rails 179 comprise
3/8 thickness, four inch width angle pieces, about 88 inches in
height, preferably made of stainless steel or other suitable steel
materials. Other designs for an elevatable mast are known to
persons of skill in the art.
[0063] Remaining with FIGS. 10 and 12, mast guide 15 comprises
guide tubes 178, one or more sets of roller assemblies 177 and
additional guide rails 179. Guide tubes 178 are joined at their
bases to mast assembly base 21, preferentially by welding. Guide
tubes 178 are preferentially arranged outwardly from the exposed
outer corners of mast 13, radially and symmetrically from the
center of mast 13, preferably such that four guide tubes 178 are
outward of the corners in both the forward/aft and side-to-side
directions, and are positioned parallel to each of mast tubes 176.
In one embodiment, guide tubes 178 are about four inches square in
section, have a wall thickness of about 3/8 inch, are about 88
inches in height, and are preferably constructed of stainless steel
or another suitable steel. Similarly to mast tubes 176, guide rails
179 are mounted at their inner face to the corners of guide tubes
178 opposite to the outer corners of mast 13. Rails 179 need not be
the full length of tubes 178 or 176, but may rather be fixed only
to that portion of the tube in contact with a roller.
[0064] Remaining with FIGS. 10 and 12, roller assemblies 177
preferably comprise rollers 192 fixed to mounts 193. Preferably,
roller 192 is a steel, yoke-style roller, having a V-groove; such
rollers with bearings rated for 12,000 pound thrust limit were
found to be acceptable. Mounts 193 are preferably an angled bracket
having an adjustable yoke fitting to accept a yoke-style roller and
to adjust the position of the roller with respect to the rail.
Other roller assembly components known to a person skilled in the
art may be acceptable. In a preferred embodiment, mast guide 15
comprises three sets of four roller assemblies 177 each, all of the
assemblies in a given set being labeled with the same suffix,
177a-177c respectively. However, sets need not have four roller
assemblies; while four opposing assemblies are advantageous, two
symmetrically opposed assemblies per set could also be used, for
instance with a further set having such opposed assemblies oriented
to a different axis than the first, thus guiding the mast in more
than one axis normal to the translation axis. Each such assembly
preferably comprises one roller 192 and mount 193, and each
assembly 177 mounted to either mast 13 or to guide tubes 178, and
placed opposing guide rails 179 on either tubes 178 or mast 13.
Rollers 192 are in rolling contact with tubes 178 or mast tubes
176, or preferably, with guide rails 179 on those tubes. This
provides a low-friction manner of transmitting forces out of the
translation axis, here vertical, from mast 13 to guide tubes 178.
In this manner, roller assemblies 177 inhibit translation of mast
13 out of that translation axis.
[0065] In a preferred embodiment, a set of lower roller assemblies
177a are mounted to mast 13, near its bottom using mounts 193,
while intermediate roller assemblies 177b, and upper roller
assemblies 177c are mounted to guide tubes 178 in a fixed
relationship to one another, with upper roller assemblies 177c
placed near the upper portion of guide tubes 178, also using mounts
193. This permits rollers lower assemblies 177a to continue to
guide mast 13 as it moves upwardly, and avoids the upper assemblies
177c interfering with upward movement of mast 13. Positioning of
sets of roller assemblies 177 along the translation axis may vary
as design criteria such as needed height of the mast, or elevation
vary, but positioning the set of lower roller assemblies 177a at or
near base plate 174, and positioning the sets of intermediate and
upper assemblies 177b, 177c about 65 and 86 inches, respectively,
above assembly base 21 was found to be acceptable.
[0066] Remaining with FIGS. 10 and 12, mast guide 15 preferably
further comprises reinforcement straps 175. Strap sets 175 should
be distributed along guide 15, and placed at points to oppose
lateral forces that might cause a guide tube to buckle. In one
embodiment, three strap sets 175a-175c are located in positions
corresponding to the vertical positions of sets of roller
assemblies 177. In another embodiment, two strap sets 175a',
175b'are roughly evenly spaced along the height of guide tubes 178,
and are about 30 and 70 inches above assembly base 21,
respectively. Strap sets 175 in these embodiments are preferably
metal bars, about three inches wide, and about 3/8 inch thick,
reaching from one guide tube 178 to the adjacent guide tube, and
welded thereto. Strap sets 17, ade of a metal suitable for welding
to guide tubes 178.
[0067] Turning to FIGS. 6A, 6C and 6D, mast-head 14 preferably
comprises mast-head plate 97, reinforcement plate 157, mast-head
frame 98, boom joints 99, boom joint supports 100, mast-head cover
plate 101, and sheeting 185. In one embodiment, mast-head 14 is
constructed of stainless steel, while in another, it is constructed
of galvanized steel. An acceptable stainless steel for the
components of mast-head 14 is 316L stainless steel. Another
acceptable steel for the components of mast-head 14 is a galvanized
hot-rolled structural channel steel, such as ASTM A36 mild steel.
Plate 97, in one embodiment, is roughly coffin-shaped viewed from
above (in FIG. 1A), is flat and about 3/8 inch thick, and has
forward, middle and rear sections, the first and last being tapered
to substantially square ends. Plate 97's length, aligned with the
longitudinal axis of the horizontal boom section, is about 156
inches, and is about 48 inches wide at its widest, in the middle
section, which is about 36 inches long. The forward section of
plate 97, adjoining horizontal boom section 20, is about 48 inches
long, and tapers to about 36 inches wide. The rear section of plate
97, supporting first counterweight 16, is about 72 inches long, and
tapers to about 36 inches wide.
[0068] Referring to FIGS. 11 and 16, the middle section of plate 97
has several holes defined through it, including access hole 156,
centered above turntable 17, and 90-degree drive hole 161, set
slightly off to the side of hole 156. Preferably, access hole 156
is partially circular about 12 inches diameter, having one side,
preferably to the side and rear, flattened off chord-wise about two
inches. Also preferably, drive hole 161 is oval and is aligned
along the radial of hole 156 normal to the flattened chord, about
four inches from that flattened portion. Drive hole 161 has a minor
and major diameters of about six and ten inches.
[0069] Referring to FIGS. 6A and 10, reinforcement plate 157 is
preferably mounted below mast-head plate 97, in the area in which
mast-head 14 is supported by mast 13, and is preferably roughly
square, about 1/2 inch thick, and about 48 inches in length and
width, and has the corners rounded off. In another embodiment
mast-head extension 18, supporting secondary counterweight 19, may
be joined to the rear section of plate 97, beyond rear frame
184.
[0070] Turning to FIGS. 6A, 6C and 6D, mast-head frame 98 lies
above the surface of mast-head plate 97, and preferably conforms
substantially to the periphery of plate 97. Frame 98 comprises a
forward transition 181, a middle section 182, a rear transition 183
and rear frame 184. The preceding four each comprise upper, middle
and lower frames, designated with the suffixes a, b and c,
respectively. Upper frames 181a-184a, and lower frames 181c-184c,
are preferably five inch C-channel beams, about 1/4 inch thick,
placed such that the legs of the beams point inwardly into
mast-head 14, and run parallel to the periphery of plate 97. More
preferably, upper frames 181a-183a, and lower frames 181c-183c, are
formed of single pieces of C-channel, having the legs notched, to
permit bending the web at the forward transition 181--middle
section 182 and middle section 182--rear transition 183 junctions.
Using single pieces lends strength to these junctions. The lower
set of legs of lower frames 181c-184c abut plate 97, while the
upper set of legs of upper frames 181a-184a abut mast-head cover
panel 101. Separating the "a" and "c" frame sets are middle frames
181b-184b, which are also preferably 5-inch C-channel beams, but
cut to three inch lengths, and set endwise between the upper and
lower frames. Middle frames 181b-184b are welded at their
"C"-shaped ends to the lower legs of upper frames 181a-184a, and
the upper legs of lower frames 181c-184c, respectively, with the
legs of middle frame 181b-184b pointed toward the interior of
mast-head 14. Middle frames are located at several locations along
the upper and lower frames, preferably at or near the points of
transition between forward, middle and rear transitions 181-183 and
rear frame 184, as well as one or more locations intermediate
thereto.
[0071] In one embodiment, each of forward transition frames 181 are
about 13 inches high, and run about 49 inches along the side edges
of the forward section of plate 97. Similarly, each of middle
section frames 182 are about 13 inches high, and run about 36
inches along the edge of the middle section of plate 97, and each
of rear transition frames 183 are about 13 inches high, and run
slightly more than about 72 inches along the side edges of the rear
section of plate 97. Preferably, a single piece of channel about
157 inches long is used for upper and lower frames 181a-183a,
181c-183c. Rear frame 184 is also about 13 inches high and runs
about 36 inches along the rear edge of plate 97. Lower frames
181c-184c are preferably both welded and bolted to mast-head plate
97. Mast-head frame 98 also comprises front frame 180, which is at
the front of mast-head plate 97, and is only a portion of the
height of frames 181-184, preferably about 3 inches, to accept
horizontal boom section 20. In one embodiment, front frame 180 is
3-inch angle bracket, 1/4 inch thick; in another, it is a tube
having a roughly three-inch square hollow section. Preferably,
sheeting 185 is mounted to mast-head frame 98 on its outward side,
and may comprise 1/8 inch 5052 aluminum sheet.
[0072] Mast-head 14 also preferably comprises upper and lower boom
joints 99a, 99b, rear boom joint 207, and boom joint supports 100.
Boom joints 99a, 99b and 207 are beams structurally connecting
horizontal boom section 20 to mast-head 14, and are preferably five
inch C-channel, having legs 188 extending from inner surface 186.
There are preferably two each of upper and lower boom joints 99a,
99b, one upper and one lower on each side of horizontal boom
section 20, placed alongside and parallel to proximal ends 62 of
beams 56, and so that outer surfaces 187 of boom joints 99a, 99b
abut the outer surface of beams 56, and inner surface 186 and legs
188 face away from horizontal boom section 20. In a particularly
preferred embodiment, upper boom joints 99 are about 156 inches
long, and may be constructed of 304L stainless steel or another
acceptable steel suitable for welding to mast-head 14. Upper boom
joints 99a extend forwardly from rear frame 184a to the forward end
of mast-head 14, at the forward end of forward transition 181a.
Lower boom joints 99b, shorter than the upper ones, extend
forwardly from rear boom joint lower joint section 207c to the
forward end of mast-head 14, at the forward end of forward
transition 181c. Boom joints 99a, 99b are joined to horizontal boom
section 20, preferably by structural bolts 206 distributed along
its length, and with rear boom joint 207, support boom section 20,
and thereby boom section 22. In addition, angle bracket 149, welded
to the exterior of forward transitions 181, is placed with one leg
flush to the opening for boom section 20, and is bolted to boom
section 20.
[0073] Upper boom joints 99a are supported above lower boom joints
99b, and above plate 97, by several boom joint supports 100, and
are preferably braced in that position by several transverse braces
163. Supports 100 are preferably sections of five-inch channel, in
which the legs run vertically, and support upper beam joints 99a at
their lower legs 188 at numerous places along their length. Two
transverse braces 163 are positioned in a transverse relationship
with each of upper boom joints 99a, between inner surfaces 186 and
mast-head frame 98. Preferably, braces 163 are short sections of
3-inch by 1/4 inch angle bracket, and are located near proximal
ends 62 of beams 56, near the joint between forward transition 181
and middle section 182, and near the joint between middle section
182 and rear transition 183. Also preferably, rear gussets 191 are
joined between boom joint inward surface 187 and upper rear frame
184a. In a particularly preferred embodiment, braces 163 are about
six inches in the dimension long, are joined such that the legs run
from inner surfaces 186 to frame 98.
[0074] Referring to FIG. 6D, rear boom joint 207 is placed
transversely between upper and lower boom joints 99a, 99b, and
immediately rearwardly of horizontal boom section 20. Rear boom
joint 207 preferably comprises upper and lower joint sections 207a,
207c, and middle section 207b. Boom joint sections 207a, 207c are
preferably five inch C-channel, and comprise distal and proximal
faces 209, 210, legs 212 rising from the proximal face, and ends
211. Upper section 207a further comprises tension cable chases 208,
and lower section 207c, longer than upper section 207a, defines
cutaway sections 213. Middle sections 207b are similarly five inch
C-channel sections, cut to three-inch lengths and joined to the
upper and lower sections in a manner similar to that used in frames
181-184. Middle sections 207b are placed to either side of proximal
end 44 of tube 40, which is exposed at flange 66a. Distal faces 209
of rear boom joint 207 abut proximal face 68a of flange 66a, as
well as proximal ends 62 of beams 56. Rear boom joint 207 is joined
to horizontal boom section 20, at these abutting surfaces,
preferably by several structural bolts 206 distributed across rear
boom joint 207.
[0075] Turning to FIGS. 14A and 14B, in another embodiment,
mast-head extension 18, for supporting secondary counterweight 19,
is attached to mast-head 14. Extension 18 comprises extension plate
217, extension frame 218 and extension cover panel 222. Extension
18 may be either a stainless steel alloy, or galvanized steel, but
the material should match that used for mast-head 14. Plate 217 is
preferably one-inch plate, and about 48 inches long, measuring
longitudinally from its point of attachment to mast-head 14. The
joined end preferably matches the rear end of mast-head 14 and is
about 36 inches wide, while the opposite, rear, end is tapered to
about 20 inches wide. Frame 218 comprises extension rear frame 219
and two side frames 220, which preferably extend from mast-head
rear frame 184 rearwardly to extension rear frame 219. Rear and
side frames 219 and 220 are constructed similar to frames 181-184,
using lengths of 5 inch C-channel forming upper frames 219a, 220a
and lower frames 219c, 220c, and short lengths, preferably three
inches, of cut channel welded therebetween, forming middle frames
219b, 220b. Frame 218 further includes angle bracket 221,
preferably 2 by 2 inch by 3/8 inch thick, attached to the front
edge of plate 217, with a vertical face aligned upwardly at that
edge.
[0076] Secondary counterweight 19 is mounted, or otherwise fixed,
within extension 18, preferably to plate 217, and preferably as
near to extension rear frame 219 as practicable, to maximize the
counterweighting effect. Should secondary counterweight 19 be
sufficient to balance instrument boom 10, first counterweight 16
may be omitted entirely. In one embodiment, secondary counterweight
19, comprising about 2,400 pounds of lead sheet, was sufficient to
balance instrument boom 10. Frame 218 is mounted to plate 217 by
welding the lower leg of lower side frames 220c and rear frame 219c
to plate 217, and by using bolts 206 to connect the two components.
Mast-head extension 18 is mounted to mast-head 14, preferably by
welding the joined, wider, end of extension 18 to the rear edge of
mast-head plate 97 and rear frame 184a-184c. In a particularly
preferred embodiment, the wider end of extension plate 217 is
welded to the rear edge of plate 97, the vertical face of angle
bracket 221 is welded to lower rear frame 184c, and the forward
ends of upper and lower side frames 220a, 220c are welded to
corresponding upper and lower mast-head rear frames 184a, 184c.
Cover panel 222 may be fixed to extension 18 using panel bolts 155.
As a further alternative, plates 97 and 217 may be formed as a
single plate.
[0077] Referring to FIGS. 6C, 6D and 10, mast-head cover 101 is
mounted to and above mast-head frame 98. Cover 101 is preferably
light plate conforming substantially in shape to mast-head plate
97, and to the periphery of mast-head frame 98. In a particularly
preferred embodiment, cover 101 comprises several 1/8 inch thick
aluminum plates, which together are roughly shaped as mast-head
plate 97. The various plates of cover 101 may be mounted to frame
98 using bolts 155.
[0078] Mast-head 14 is preferably constructed as follows. Joinder
is preferably by welding, more preferably by a MIG (gas metal arc)
welding process. A welding process using a 200 ampere MIG welder,
manufactured by Miller Electric Mfg. Co., 1635 West Spencer Street,
P.O. Box 1079, Appleton, Wis. 54912, has been found to be
satisfactory, although a higher amperage rating may be desirable to
reduce any need for preheating the aluminum material. A pure argon
shielding gas was acceptable. A SPOOLMATIC 30A automatic wire feed
system, also by Miller Electric, was used to feed a 0.035 inch ER
4043 aluminum alloy wire to the MIG welder. If necessary,
preheating may be accomplished using an oxy-acetylene or propane
torch. Other methods of accomplishing joinder between metal objects
known to a person of skill in the art may be satisfactory, such as
TIG-type welding, and will depend upon the specific compositions
and heat treatment of the materials used. In addition, the above
techniques are suitable for horizontal and vertical boom sections
20, 22, mast assembly 12, and box joint 59.
[0079] Referring to FIGS. 6C and 6D, mast-head 14 is constructed in
the following preferable sequence: plate 97 is pre-drilled with
holes to accept bolts 206, and is supported for the construction
process slightly higher at the forward and rear ends to induce a
slight "sag" in the area to be joined to middle section 182. This
sag is induced to counteract the hogging effect created by applying
the loads to mast-head 14, counterweights 16, 19 and horizontal and
vertical boom sections 20, 22 at its two ends. A slight, visible,
sag at that middle section was found to be acceptable. The lower
legs of lower frames 181c-184c of frame 98 may also be pre-drilled
with holes for bolts 206. Further, referring now to FIG. 6A, the
legs of the single pieces comprising upper frames 181a-183a and
lower frames 181c-183c are preferably previously notched to permit
the bends in the web to form the angled transitions between forward
transition 181 and middle section 182 and between middle section
182 and rear transition 183. In addition, one end of the single
pieces, and both ends of rear frames 184a, 184c, are preferably
previously bevel cut in order to facilitate miter joints at the
angled transitions between rear transition 183 and rear frame 184.
Tack-welding, and clamping may be utilized in this construction
process in order to counteract heat expansion difficulties.
[0080] Returning to FIGS. 6C and 6D, the lower leg of the single
piece of channel comprising lower frames 181c-183c is placed so
that its forward end is aligned with the forward end of plate 97,
and permits proper placement of lower boom joints 99b. Further, its
legs face inward, and its five-inch face is substantially flush
with the edge of plate 97 in the forward transition, and
preferably, its bolt holes are aligned to those in plate 97. Lower
frame 181c-183c is then welded along both the inner and outer edges
of the lower leg to the upper surface of plate 97 in forward
transition 181c. Referring now to FIG. 6A, the single piece is then
bent to form the angled transition between forward transition 181
and middle section 182, and lower frame 181c-183c is welded along
both the inner and outer edges of the lower leg to the upper
surface of plate 97 in middle section 182c. Next, the single piece
is bent to form the angled transition between middle section 182
and rear transition 183, and lower frame 181c-183c is welded along
both the inner and outer edges of the lower leg to the upper
surface of plate 97 in rear transition 183c. Next, this process is
repeated with lower frame 181c-183c located on the opposing side of
plate 97. Finally, returning to FIGS. 6A, 6C, the lower leg of
lower frame 184c of rear frame 184 is welded along both the inner
and outer edges to the upper surface of plate 97, and the beveled
edges at the ends of lower frame 184c are welded to the beveled
ends of the single pieces forming lower frames 181c-183c. Once all
lower frames 181c-184c are welded in place, they are bolted to
plate 97 using bolts 206 (see FIG. 6D).
[0081] Next, referring to FIGS. 6C and 6D, proceeding sequentially
around lower frames 181c-184c, one C-shaped end of each of middle
frames 181b-184b is welded in place to the upper legs of lower
frames 181c-184c. Again, the legs of the middle frames 181b-184b
face inwardly, and the opposing face is aligned with the edge of
plate 97. The order in which this is accomplished may vary. In one
embodiment, there are middle frames located at: the forward end and
midpoint of forward transition 181, at the junction of forward
transition 181 and middle section 182, at middle section 182's
midpoint and its junction with rear transition 183, three
distributed along the length of rear transition 183, at the rear of
rear transition 183, and at each end of rear frame 184. Placement
of middle frames is also visible in FIGS. 14A and 14B.
[0082] Next, remaining with FIGS. 6C and 6D, the lower leg of the
single piece of channel comprising lower frames 181c-183c is placed
above lower frame 181c so that its forward end is aligned with the
forward end of plate 97, and permits proper placement of upper boom
joints 99a. Further, its legs face inward, and its five-inch face
is substantially flush with the edge of plate 97 in the forward
transition. Upper frame 181a-183a is then welded to the second
C-shaped ends of middle frames 181b in the forward transition.
Then, turning to FIG. 6A, the single piece is bent to form the
angled transition between forward transition 181 and middle section
182, and the lower leg of upper frame 181a-183a is welded to the
second C-shaped ends of middle frames 182b in the middle section.
Next, the single piece is bent to form the angled transition
between middle section 182 and rear transition 183, and upper
181a-183a is welded is to the second C-shaped ends of middle frames
183b in the rear transition. Next, this process is repeated with
upper frame 181a-183a located on the opposing side of plate 97.
Finally, the lower leg of upper frame 184a of rear frame 184 is
welded to the second C-shaped ends of middle frames 184b in the
rear transition, and the beveled edges at the ends of upper frame
184a are welded to the beveled ends of the single pieces forming
upper frames 181a-183a.
[0083] Next, turning to FIGS. 6C and 6D, rear boom joint lower
frame 207c, which like the lower frames, has preferably been
pre-drilled, is aligned forward of access hole 156 (in FIG. 6A) to
corresponding bolt holes in plate 97. Lower frame 207c is placed
with its legs 212c at ends 211c abutting the legs at the forward
ends of lower frames 182c. The lower leg 212c of lower frame 207c
is then welded in place to plate 97, and bolts 206 are installed.
Welds on upper, lower or rear boom joints 99a, 99b, 207 on outer
surfaces 187, or on distal faces 207a-207c, should be avoided, at
least those at or above three inches above mast-head plate 97.
These surfaces are preferably left smooth for a close fit to
horizontal boom section 20. However, if necessary these surfaces
may be welded upon, if appropriate finishing measures, such as
beveling and grinding, are used to ensure a smooth surface.
[0084] Next, remaining with FIGS. 6C and 6D, one of lower boom
joints 99b, like 207c preferably pre-drilled, is aligned with the
bolt holes in plate 97, which places boom joint 99b's forward end
flush with the forward end of plate 97, and in contact with lower
frame 181c, and its rear end abutting distal face 209 of lower rear
boom joint 207c. Outer surface 187 faces inward, away from frame
98. Legs 188 at the forward end of lower boom joint 99b may be
trimmed away to form a good joint with lower frame 181c, and to
obtain the proper positioning; it is important that the distance
between boom joint outer surfaces 187, for both upper and lower
boom joints 99a, 99b, is matched closely to the overall width of
horizontal boom section 20, in order to obtain a snug fit and deter
"wobbling" of instrument boom 10. This width may vary depending
upon material chosen for construction, but in one embodiment using
a stainless steel for construction of mast-head 14, 25.125 inches
was found acceptable for the distance between surfaces 187. To
account for the galvanized layer's thickness, a slightly greater
distance may be needed if galvanized steel is used. Lower leg 188
of boom joint 99b is welded to plate 97, its rear end to lower rear
boom joint 207c, and its forward end to lower frame 181c. Lower leg
188 is then bolted to plate 97. This process is then repeated with
the other lower boom joint 99b.
[0085] Next, the several supports 100 are fixed in place. Referring
to FIGS. 6A, 6C and 6D, supports 100, preferably twelve, are
located as follows. A first six are cut to three-inch length: two
each between upper and lower boom joints 99a, 99b, near forward end
189 of upper beam joints 99a about at the midpoint of lower boom
joint 99b, and at the junction of lower boom joint 99b and lower
rear boom joint 207c. A second six are cut to eight-inch length:
two each about even with sheave support 154, about at the
transition between middle section 182 and rear transition 183, and
about at the midpoint of rear transition 183. FIGS. 14A and 14B
also depict placement of some of supports 100. All supports 100 are
placed with their legs pointed outwardly, and the 5-inch face
inwardly. The first six, three-inch supports, are welded at one
C-shaped end to the upper of lower boom joint legs 188, the last
extending onto the upper of rear boom joint legs 212c. The second
six, eight-inch supports are welded at one C-shaped end to plate
97, in two lines extending rearwardly from lower boom joints
99b.
[0086] Next, remaining with FIGS. 6A, 6C and 6D, one of upper boom
joints 99a is added. With outer surface 187 facing inwardly, away
from frame 98, forward end 189 of boom joint 99a is placed above
lower boom joint 99b's forward end, supported on the lower of legs
188 by supports 100. Forward end 189 should be flush with the
forward end of plate 97, and in contact with upper frame 181c. Rear
end 190 will abut the legs of upper rear frame 184a. Legs 188 at
forward end 189 of upper boom joint 99a may be trimmed away to form
a good joint with upper frame 181a, for reasons noted above. Then,
the lower of legs 188 are welded to the C-shaped ends of supports
100, and forward and rear ends 189, 190 are joined to upper frame
181a and upper frame 184a, respectively. The weld to upper frame
184a may be made on boom joint outer surface 187. This process is
then repeated with the other upper boom joint 99a.
[0087] Turning to FIGS. 6A and 11, four transverse braces 163 are
added; they are placed between upper boom joints 99a and upper
middle section frames 182a, two at the forward ends and two at the
rear ends, of frames 182a. The ends of braces 163 join boom joint
inner surface 186 and the inner face of frames 182, between the
legs, and are welded thereto.
[0088] Turning to FIGS. 6D, rear boom joint middle frames 207b are
placed to either side of center of lower frame 207a, leaving a gap
between them of at least about five inches. One C-shaped end of
each of middle frames 207b is joined to the upper of legs 212 by
welding, with legs 212 of middle section 207b facing
rearwardly.
[0089] Next, upper frame of rear boom joint 207a is added, the
lower of its legs 212 joined to the top of the second C-shaped ends
of middle frames 207b, and its C-shaped ends 211c abutting and
joined to boom joint outer surface 187. Next, in FIG. 6C, angle
brackets 149 are welded to the forward ends of frames 181a, 181c
and boom joints 99a, 99b. Finally, sheeting 185 is joined to the
outer surfaces of frames 181-184, preferably by riveting, and
mast-head cover plate is added using bolts 155 fixed preferably to
upper legs of frames 98 or upper boom joints 99a.
[0090] Turning to FIGS. 10 and 11, mast-head 14 is preferably
supported by turntable 17. Mast-head plate 97 is mounted to
reinforcement plate 157 below, and thence to upper plate 159.
Reinforcement plate 157 distributes the load applied by upper plate
159. Turning to FIG. 16, turntable 17 is itself supported on mast
13 by lower plate 158 and rotary bearing assembly 160. Bearing
assembly 160 has diameter d7, which is preferably about 30 inches
and is suitable for supporting a load of about 40,000 pounds.
Turntable 17 permits rotation of mast-head 14 relative to mast 13,
and thus to transport body 8, and movement axis 5.
[0091] Remaining with FIGS. 10 and 11, mast rotation motor 88,
reducer 89 and 90-degree drive 90 are mounted within mast-head 14,
to mast-head plate 97, either directly or indirectly. Motor 88 is
joined to reducer 89 using a shaft, and preferably operates at
about 1140-1180 R.P.M. Reducer 89 provides a reduced output shaft
R.P.M., preferably a ratio of about 1:6000. Output speed of reducer
89 is preferably such that deploying of instrument boom 10 occurs
at about 15 degrees per minute. Reducer 89's output shaft is joined
to a wire cage coupling 193 (in FIG. 15), which comprises a cover,
a first toothed transmission disk 194a, coupled to reducer 89, and
offset a short distance along the shaft's axis, a second toothed
transmission disk 194b, joined by a shaft to the input of 90-degree
drive 90. Wire cage 195 is formed by tightly looping wire around
the teeth of one transmission disk and around the teeth of the
second, and repeating the process with other teeth, until each
tooth is bound to one or more teeth with one or more loops of wire.
Such a wire cage coupling 193 is advantageous because it provides a
lower torque loss than a conventional rubber bushing, and little
backlash. A model RK6-25N12 turntable bearing by Kaydon Corp.,
having an outer diameter of 29.5 inches, was found to be
acceptable. A 1/2 H.P. SM-Cyclo 4000 electric motor was found to be
acceptable for mast rotation motor 88. A Sumitomo model no.
CHHJ4145DB4-7569 was found to be acceptable for reducer 89, and HUB
CITY brand 90-degree drive, providing a 1:1 ratio, was found to be
acceptable for drive 90.
[0092] Turning to FIGS. 11 and 16, drive 90 translates the output
shaft rotation from coupling 193 to rotation in a second shaft in
the vertical plane via a gearset (not shown). An output shaft from
drive 90, passing through drive hole 161, is fixed to spur gear
196, which drives ring gear 197 fixed to lower plate 158 of
turntable 17. As drive 90 is fixed to mast-head 14, and ring gear
197 to lower plate 158, and thence to chassis 6 via mast 13,
operation of mast rotation motor 88 results in rotation of
instrument boom 16. Rotation is permitted at least between the
deployed position in FIG. 1C and the stowed position in FIGS. 2A
and 2B. The deployed position in the preferred embodiment is about
ten degrees rearward of a position normal to movement axis 5, while
the stowed position is rearward and about thirteen degrees off
movement axis 5.
[0093] Returning to FIGS. 1A and 1B, operator compartment 107,
preferably located in the rearward portion of transport body 8,
includes operator station 110, which permits an operator to control
items such as instrument boom 10, emitter 112 and low-speed drive
system 120. Drive system 120 may also be controlled by a driver in
cab 4. Further equipment found in the preferred embodiment include
video cameras 118 and worklights 119, which may also be operated
from operator station 110.
[0094] Steady and slow forward movement of mobile inspection unit 1
along movement axis 5 (in FIG. 1A) is desirable for several
reasons. First, in operation, a driver in cab 4 will control the
direction of movement along movement axis 5 using a conventional,
installed, steering system, just as along a roadway during normal
movement. The driver or the operator at station 110 would operate
low-speed drive system 120 to control the speed of inspection unit
1. In operation, side clearance 128 (in FIG. 1C) may be as little
as 21 inches, depending upon the size of target 131 and the size of
instrument boom 10. Thus, slow forward motion permits the driver to
maintain this clearance more easily. Further, slow passage will
increase the amount of time in which any particular portion of
target 131 remains within scanning zone 114, increasing likelihood
of detection of the sought after contraband or other items. In
addition, accuracy is increased, as a smooth forward motion will
minimize jerking associated with use of a conventional transmission
of main drive system 3. Jerking would likely result in motion and
flexure of instrument boom 10 relative to emitter 112, with
resultant inaccuracies of detection based upon received signals. In
a preferred embodiment, movement of instrument boom 10 relative to
emitter 112, as measured at distal end 29a of lower boom segment 26
(visible in FIG. 1D), should be less than about one inch in any
direction.
[0095] Turning to FIG. 2B, to permit such steady and slow forward
movement, low-speed drive system 120 is preferred to power a rear
set of wheels 7. Low-speed drive system 120 utilizes electric power
from generator 102 to power electric motor 121. Motor 121 may run
at up to 2000 RPM, and thus reducer 122 is used to reduce the
rotational speed transmitted from the shaft of motor 121. From
reducer 122, power is transferred, via transfer case 124, to
reversed differential 123. Differential 123 converts rotation
transverse to the axle of the shaft of reducer 122 to drive the
rear set of wheels 7 of mobile transport 2, and is directed from
the rear of wheels 7 in order not to interfere with main drive
system 3. During operation, an operator at operator station 110, or
the driver in cab 4 (both visible in FIG. 1A), can control the
speed of motor 121 to propel mobile transport 2 at various speeds
past a target 131; further, speed may be closely controlled because
electric motor 121's speed may be adjusted up and down in small
increments. These speeds may range from about 15 inch/second to
about 60 inch/second. Transfer case 124 permits motor 121 and
reducer 122 to be completely disengaged from reversed differential
123, permitting the rear set of wheels 7 to rotate freely during
periods when mobile transport 2 is being propelled by main drive
system 3. In the preferred embodiment, low-speed drive system 120
incorporates a conventional interlock preventing it from being
engaged if main drive system 3 is engaged. Main drive system 3
similarly incorporates a conventional interlock to prevent it from
being engaged if low-speed drive system 120 is engaged.
[0096] In order for mobile inspection unit 1 to most accurately
inspect target vehicles or cargo, instrument boom 10 should provide
a high degree of rigidity and torsional resistance. As discussed,
rigidity and torsional resistance is important to maintain proper
alignment between sensor packages 24 and emitter 112. Mast-assembly
12, particularly mast-head 14, and horizontal boom section 20,
support much of the load applied by the sensors and the weight of
instrument boom 10, both vertical and torque, and provide much of
that rigidity.
[0097] Turning to FIGS. 6A and 6B, horizontal boom section 20
comprises longitudinal and transverse axes 21a, 21b, and a first
support member, preferably inner tube 40, having outer surface 42,
and longitudinal axis 41, proximal end 44 and distal end 46.
Preferably, longitudinal axis 41 is coincident with axis 21a.
Although the first support member is described and depicted as a
hollow tube or cylinder, it could also be a solid rod; however a
hollow tube has the advantage of providing additional torsional
resistance compared to a solid rod of identical unit weight.
Similarly, while inner tube 40 is depicted as being circular in
cross section, it could also be oval or some other annular cross
section. Further, the configuration will depend upon the specific
materials utilized and the loads to be applied. In a preferred
embodiment, inner tube 40 is formed as a hollow aluminum cylinder,
having an annular cross-section, and an outer diameter d1,
thickness t1 and length n1. In a particularly preferred embodiment,
d1 is about 4 inches, t1 is about 1/2 inch, n1 is about 200 inches,
and inner tube 40 is constructed of T6 6061 aluminum. While ANSI
type T6 6061 aluminum has been found to be acceptable for tube 40,
and for other components, other types of heat-treated or
high-strength aluminum, or other metals may be acceptable depending
upon the design criteria.
[0098] Continuing with FIGS. 6A, 6B and 8A, horizontal boom section
20 also comprises a plurality of second support members, preferably
eleven outer tube segments, 48a-48j; however the number and length
of such segments may vary upwardly from one, and will depend upon
the specific materials utilized and the loads to be applied. Outer
tube segment 48a has surface 50a, proximate end 52a and distal end
54a. Similar features on outer tube segments 48b-48j are labeled
utilizing those respective suffixes. Outer tube segments 48a-48j
may be of a non-circular cross section, and may be of a different
cross-sections or length from one another, however their inner
dimensions must be larger than outer diameter d1 of inner tube 40.
In a preferred embodiment, outer tube segments 48a-48j are formed
as hollow aluminum cylinders, each having an annular cross-section,
and an outer diameter d2 and thickness t2. Segments 48a-48j have
lengths n2a through n2j, respectively. In a preferred embodiment,
d2 is about 8 inches, t2 is about 1/2 inch, n2a through n2c are
about 151/2 inches, n2d is about 91/2 inches, n2e through n2i are
about 231/2 inches, and n2j is about 211/2 inches. The number of
segments, and their exact dimensions may vary, depending upon
design criteria. In another embodiment, only nine segments are
used, and lengths n2a through n2c are adjusted to compensate,
preferably by increasing them to about 181/2 inches. Preferably,
outer tube segments 48a-48j are constructed of 6061 T6 aluminum,
although other materials may be acceptable.
[0099] Turning now to FIGS. 6A, 6B and 8, horizontal boom section
20 also comprises third support members, preferably beams 56,
having one or more legs 58a and 58b, and inward surface 60. In a
preferred embodiment, beams 56 are C-channel beams constructed of
aluminum, and are also shown in FIG. 4. Also in this embodiment,
inward surface 60 lies between legs 58a, 58b, which rise from the
planar surface of beam 56, and run down its longitudinal axis.
Beams 56 also have proximal end 62 and distal end 64. In this
preferred embodiment, beams 56 have height h3, thickness t3 and
legs 58a, 58b have depth x3. In this preferred embodiment, distal
end 64 extends about 10 inches beyond flange 66K to facilitate box
joint 59. In a particularly preferred embodiment, h3 is about 10
inches, t3 is about 0.5 inch, x3 is about five inches, n3 is about
210 inches, and beams 56 are constructed of 6061 T6 aluminum.
[0100] Horizontal boom section 20 also comprises a number of HBS
flanges 66, arrayed in a spaced relationship to one another.
Referring to FIGS. 6A and 6B, in a preferred embodiment there are
eleven HBS flanges 66a-66k. HBS flanges 66a and 66k may be referred
to as end caps due to their terminal positions on horizontal boom
section 20 and inner tube 40. Turning to FIGS. 4, 5A and 5B, HBS
flange 66b includes proximal face 68b, and distal face 70b, as well
as upper edge 72b, lower edge 73b and side edges 74b. HBS flange
66b also incorporates flange hole 76b which has flange hole edge
77b, and proximal and distal grooves 78b, 79b, located respectively
upon proximal and distal faces, 68b, 70b. Grooves 78b, 79b are
circular, and concentric to flange hole 76b, and correspond to the
dimensions of outer tube segments 48. Grooves 78, 79 are preferably
included, as they aid alignment of outer tube segments 48 during
assembly and construction of horizontal boom section 20, however,
they could be omitted, with the lengths of the outer tube segments
reduced commensurately, and proximal and distal ends 52, 54
abutting directly upon faces 70, 68 of HBS flanges 66. Grooves 78b,
79b have an outer diameter corresponding to diameter d2, and the
groove has a thickness corresponding to thickness t2. Further,
grooves 78b, 79b have depth g4, from the face inward, sufficient to
permit a corresponding distal end 54a of tube segment 48a or
proximal end 52b of segment 48b to be inserted therein, and for the
segments to be supported therein. In a preferred embodiment, d2 is
eight inches, t2 is 1/2 inch and g4 is about 1/4 inch.
[0101] HBS flange 66b also preferably includes channel cuts 75b,
which, in one embodiment, are relatively shallow depressions formed
in upper and lower edges 72b, 73b, about 3/4 inch deep into the
edges, and about four inches along the edges, and preferably
closely conform to the shape of inward surface 60 and legs 58a, 58b
of beams 56 to permit congruent engagement therewith. HBS flange
66b also incorporates two cable chases 80b permitting passage of
tensioning cable 150. In a preferred embodiment, there are two
cable chases, one each to the sides of flange hole 76b. In a
preferred embodiment, HBS flange 66b is constructed of aluminum
plate. Flange hole 76b and cable chases 80b can be removed by
various machining processes for cutting thick metal pieces known to
persons of skill in the art, such as a plasma cutter, or a water
jet cutter. In this embodiment, HBS flange 66b has height h4,
thickness t4 and width w4. Flange hole 76b has diameter d4, and
cable chases 80b have diameter c4. In a particularly preferred
embodiment, flange 66b is constructed of 6061 T6 aluminum, h4 is
about 10 inches, t4 is about one inch, w4 is about 23 inches, c4 is
about 11/2 inches, and d4 is slightly greater than d1, about 4 1/16
inches. HBS flanges 66a, 66c-66k have similar features labeled
using those respective suffixes. HBS flange 66b will ordinarily be
typical, save for the varying position of cable chases 80a-80k, but
need not be. In addition, end caps 66a, 66k, which only adjoin one
outer tube segment apiece, will ordinarily omit proximal groove 78a
and distal groove 79k, respectively. Flange holes 76a-76k should be
aligned to an axis coincident to axis 41. Returning to FIGS. 6A and
6B, in a particularly preferred embodiment, the spacing between the
opposing distal and proximal faces of adjacent HBS flanges (e.g.
a-b is between distal face 70a and proximal face 68b, preferably
corresponding to a distance about 1/2 inch less than lengths
n2a-n2j of outer tube segments 48a-48j) is as follows: a-b through
c-d, about 15 inches; d-e, about 9 inches; e-f through j-k, about
23 inches. The number of flanges, and the spacing between them may
vary, depending upon design criteria, such as the lengths of the
outer tube segments. In another embodiment, only nine segments are
used, and thus there are only ten flanges, in which case the
spacing is adjusted to compensate.
[0102] To accommodate passage of tensioning cable 150 through each
of flanges 66a-66k, as cable 150 moves downwardly and outwardly
from proximal end cable attachment 151 to sheave 153 toward distal
end cable attachment 152, each successive cable chase 80 is at a
lesser height above the flange's lower edge 73 (visible in FIG.
8A). Tensioning cables 150 provide an upward force upon proximal
and distal end attachment points 151, 152. Cables 150 are
preferably 5/8 inch braided stainless steel cables, and are
terminated by threaded studs, which in one embodiment, are about
11/4 inches in diameter, and may be secured by use of hardware
known to a person of ordinary skill. The upward force is
transmitted from those attachment points to rear frame 184 of
mast-head 14 and to terminal flange 198 and ears 146 of vertical
boom section 22.
[0103] Turning to FIGS. 10 and 11, sheaves 153, preferably used to
redirect cables 150, cause the tension in cables 150 to act
upwardly upon the structure at its ends. Sheaves 153 are located
near the center of mast-head 14, preferably adjacent to access hole
156, and are supported by supports 154. Sheaves 153 are preferably
about five inches in diameter, and supported upon a 11/4 inch bolt.
Sheave supports 154 raise sheaves 153 above plate 97, and are
preferably square tubing, having a four-inch hollow square section
and 3/8 inch wall thickness, cut to about eleven inches long, onto
which sheave 153 is mounted. The upward forces serve to reduce the
"hogging" effect caused by supporting mast-head 14, counterweights
16, 19 and horizontal and vertical boom sections 20, 22 at an
intermediate position, rather than at their ends. In addition,
application of differing tension to cables 150 permits inducement
of a "twist" of horizontal boom section 20 along its longitudinal
axis. Such an induced twist may be used to counteract small
misalignments of boom sections 20 and 22 during construction or
otherwise. Tensioning cables 150 are internal to mast-head 14 and
horizontal boom section 20, and are substantially horizontal, as
sheaves 153 provide an upward deflection of about eleven inches
above plate 97.
[0104] Returning to FIG. 4, horizontal boom section 20 preferably
also includes upper HBS panels 81, which have edges 82. Preferably,
HBS panels 81 are sufficiently wide to run from upper leg 58b of
one beam 56 to upper leg 58b of the opposing beam 56, and together
run the length of horizontal boom section 20. Panels 81 are mounted
to legs 58b, preferably using bolts 155. Panels 81 provide access
to the interior of horizontal boom section 20, protect the cabling
and other components of the instrument boom 10, and are preferably
made of about 1/8 inch aluminum sheet. Further, in a preferred
embodiment, sensor packages 24 are mounted to brackets 162,
preferably by welding, which are in turn mounted to the underside
of legs 58a, preferably using bolts 155. Interior face 86 of sensor
packages 24, and the interior of brackets 162 span the gap between
legs 58a. In a preferred embodiment, sensor packages 24 and
brackets 162 substantially cover the lower surface of legs 58a, and
extend for substantially all of the portion of the underside of
horizontal boom section 20 not covered by mast-head plate 97.
[0105] Horizontal boom section 20 is preferably assembled and
joined by the following method. Joinder is preferably by MIG
welding, as above. Referring to FIGS. 4 and 6B, prior to any
welding, one of beams 56 is laid on the flat outer surface, with
inward surface 60 and legs 58a, 58b facing upwardly. HBS flange 66a
is aligned to proximal end 62, with side edges 74a of flange 66a
abutting inward surface 60 and with upper and lower legs 58a, 58b
congruently engaging channel cuts 75a. Next, flanges 66b-66k are
placed with side edges 74b-74k abutting inward surfaces 60, and
with upper and lower legs 58a, 58b congruently engaging channel
cuts 75b-75k. Flanges 66b-66k, however, are not aligned to their
final locations as indicated in FIGS. 6A, 6B, but rather are
displaced about eight inches towards distal end 64 of beams 56,
with flange 66k being located near distal end 64. Clamps may be
used to retain flanges 66 in position. Next, the second of beams 56
is aligned parallel to the first, with inward surfaces 60 facing
one another, and placed on top of the exposed side edges 74a-74k.
This beam 56 is fitted to the flanges, side edges 74a-74k abutting
inward surface 60, and upper and lower legs 58a, 58b congruently
engaging channel cuts 75a-75k. The entire assembly is then
compressed, beams 56 pressed firmly onto channel cuts 75a-75k;
again, clamps may be used to retain flanges 66 in position. This
assembly is then turned so that is rests upon lower legs 58a and
lower edges 73a-73k.
[0106] Remaining with FIGS. 4 and 6B, inner tube 40 is then
inserted into flanges 66 at flange holes 76a-76k, starting at hole
76k. Surface 42, at proximal end 44 of tube 40, is aligned with
hole 76k, and then pushed into it from distal face 70a. Once
proximal end 44 has emerged from distal face 70a, outer tube
segment 48j is interposed between flanges 66k and 66j, and inner
tube 40 pushed therethrough. Tube 40 then reaches distal face 70b
of the next flange 66j. Outer tube segment 48j is permitted to
rest, or hang, loosely upon surface 42 of tube 40. This process is
then repeated until proximal end 44 of tube 40 is substantially
aligned to proximal face 68a, of end cap 66a.
[0107] Once in position, flange 66a is joined to surface 42 of
inner tube 40. A weld bead is laid along the interface of flange
hole edge 77a and surface 42 at either or both of proximal face 68a
or distal face 70a. Flange 66a may now be welded to beams 56, first
inward surface 60 of one of beams 56, welded to side edge 74a, and
then the other, by applying a bead along the interface
therebetween, on first proximal face 68a, then distal face 70a.
Next, outer tube segment 48a is placed in a concentric position
outside inner tube 40 (also visible in FIG. 8A), with proximal end
52a fitting into distal groove 79a on flange 66a. Next, the
adjacent flange 66b is moved towards flange 66a from its displaced
position, so that distal end 54a of segment 48a fits into proximal
groove 78b on flange 66b. In this way, outer tube segment 48a is
supported by the two adjacent flanges 66a, 66b by grooves 79a, 78b,
and preferably fits therein the full 1/4 inch depth. Next, edges
74b of flange 66b are partially welded to inward surface 60 at
distal face 70, using one- or two-inch bead lengths. Next, ends
52a, 54a are preferably also partially welded, using one- or
two-inch bead lengths, to distal face 70a and proximal face 68b to
retain outer tube segment 48a in position. Partial welding of the
HBS flanges and the outer tube segments permits some flex, or
"give" so that should there be any need to adjust their alignment,
or to adjust the alignment of the structure, that may more easily
be done. Further, should the structure begin to bow due to the
welding process, it also permits using a reverse welding sequence
when finishing the weld to cancel out the bowing effect.
[0108] Continuing with FIG. 6B, flange 66b is joined to inner tube
40's surface 42. A weld bead is laid along the interface of flange
hole edge 77b and surface 42 at distal face 70b, because proximal
face 68b is covered by tube segment 48a. Then, repeating the above
sequence, outer tube segment 48b is placed in a concentric position
outside inner tube 40, with proximal end 52b fitting into distal
groove 79b on flange 66b. Next, the adjacent flange 66c is moved
towards flange 66b from its displaced position, enabling distal end
54b of segment 48b to fit into proximal groove 78c, and flange 66c
and tube segment 48b are partially welded into position. This
process is repeated for flanges 66d-66k, and for tube segments
66c-66j, sequentially welding the inner tube to a first flange,
fitting a tube segment to the groove of the first flange, sliding
the second flange into position and fitting its groove to the
segment, and welding the flange and tube segment into place.
Finally, end cap 66k is placed adjacent to tube segment 48j, and
groove 78k fitted to end 54j. Distal face 70k of flange 66k will be
aligned substantially to distal end 46 of tube 40, and will be
about ten inches short of distal ends 64 of beams 56. Finally, the
partial welds between HBS flanges 66 and beams 56, and between tube
segments 48 and flanges 66 are filled in, completing the welds. A
reversed welding sequence may be used to counteract bending due to
welding, if needed. Naturally, this process could be accomplished
in reverse order, beginning with placement of inner tube 40 into
HBS flange 66a, or with the flanges initially displaced toward
proximal end 62 of beams 56.
[0109] Next, proximal ends 52a-52j of outer tube segments 48a-48j
are welded to distal faces 70a-70j, and distal ends 54a-54j are
welded to proximal faces 70b-70k. Finally, flange 66b may now be
welded to beams 56, inward surface 60 of one of beams 56, and then
the other, welded to side edge 74b, by applying a bead along the
interface therebetween, preferably on both of proximal face 68b and
distal face 70b. This process may be repeated until both of beams
56 are welded to each of side edges 74a-74j. However, the sequence
in which the edges are welded to the beams may be varied, such as
by alternating edges, or by welding opposing edges first.
Similarly, flanges 66 may be joined to beams 56 prior to welding
outer tube segments 48 to flanges 66. The particular order may be
affected by the need to counteract the effects of heat expansion,
which may vary with ambient temperature. Next, referring to FIG. 4,
panel 81 and brackets 162 are mounted using bolts 155.
[0110] Vertical boom section 22 preferably comprises lower boom
segment 26 and upper boom segment 28. Referring to FIGS. 3 and 9,
segments 26, 28 preferably comprise longitudinal and transverse
axes 25a, 25b and 27a, 27b, respectively. Upper boom segment 28 has
distal and proximal ends 29b, 30b, and includes beam segments 139b,
which have beam segment ears 146, longitudinal axes 140, inward
surface 141a, proximal end 142a and distal end 143a. Lower boom
segment 26 has distal and proximal ends 29a, 30a, and includes beam
segments 139a, which have longitudinal axes 140, inward surface
141b, proximal end 142b and distal end 143b. Beam segments 139a,
139b may also have one or more legs, preferably inner leg 144 and
outer leg 145. In a preferred embodiment, beam segments 139a, 139b
are C-channel beams having inward surface 141 between legs 144,
145, which rise from the planar surface of beam segments 139a and
139b, and run down their longitudinal axes. In this preferred
embodiment, beam segments 139a, 139b have width w6, thickness t6,
inner and outer legs 144, 145 have depth x6, and beam segment 139b
has length n6b. In this preferred embodiment, outer legs 145 of
beam segments 139b are extended past VBS flange 134a to form ears
146. In a particularly preferred embodiment, w6 is about ten
inches, t6 is about 1/2 inch, x6 is about five inches, and n6b is
about 85 inches. Also in this embodiment, beam segment 139a, n6a,
is about 84 inches, not including ear 146. However, beams 56 and
beam segments 139a and 139b may also omit ears 146 used to
construct box joint 59, by utilizing other methods of joining
perpendicular beams known to persons of skill in the art. Beam
segments 139a, 139b are preferably constructed of 6061 T6
aluminum.
[0111] Referring to FIG. 9, upper and lower boom segments 28, 26
further comprise several VBS flanges 134, in a spaced relationship
relative to one another (depicted in FIGS. 1D and 9). In a
preferred embodiment, there are VBS flanges 134a-134i, the first
five on upper boom segment 28, and the latter four on lower boom
segment 26. Referring also to FIGS. 7A and 7B, VBS flange 134a
includes outer edge 136a, inner edge 135a, side edges 137a,
proximal face 172a and distal face 173a. VBS flange 134a further
incorporates one or more flange holes 170a, flange hole edge 171a,
and channel cuts 138a. In a preferred embodiment, channel cuts 138a
are relatively shallow depressions formed in inner and outer edges
135a, 136a, about 3/4 inch deep into the edges, and about four
inches along the edges, and preferably closely conform to the shape
of inward surface 141a, 141b and legs 144, 145 of beam segments
139a, 139b to facilitate congruent engagement therebetween (see
FIG. 3). In a preferred embodiment, VBS flange 134a has two flange
holes 170a, spaced apart, and is constructed of aluminum plate, as
with HBS flanges 66. VBS flanges 134b-134i comprise similar
elements labeled using those respective suffixes. Flange holes
170a-170i should be aligned parallel to axes 25a, 27a. Referring to
FIGS. 8A, 8B and 9, in a preferred embodiment, in upper boom
segment 28, flange 134a is located near proximal end 142b of beam
segments 139b, but below ears 146, flange 134e is located at distal
ends 143b, and flanges 134b-134d are spaced therebetween. Remaining
with FIG. 9, similarly, on lower boom segment 26, flange 134f is
located at proximal end 142a of beam segments 139a, and flange 134i
is located at distal ends 143a, while flanges 134g, 134h are spaced
therebetween. Turning to FIGS. 7A and 7B, in this embodiment, VBS
flange 134a has height h5, thickness t5, width w5, and flange hole
170a has diameter d5. In a particularly preferred embodiment, VBS
flange 134a is constructed of 6061 T6 aluminum, h5 is about nine
inches, t5 is about one inch, d5 is about 4 1/16 inches, and w5 is
about 24 inches. Flange 134a will ordinarily be typical of VBS
flanges 134a-134i, but need not be, which may differ depending upon
design criteria for the segments. Returning to FIGS. 1D and 9, in a
particularly preferred embodiment, the spacing between the opposing
distal and proximal faces of adjacent VBS flanges (e.g. a-b is
between distal face 173a and proximal face 172b) is as follows: a-b
through d-e, about 23.5 inches; and f-g through h-i, about 22
inches. VBS flanges are spaced enough to accommodate hinge 31.
[0112] Referring to FIGS. 3 and 9, upper and lower boom segments
28, 26 each further comprise one or more upper and lower vertical
tube segments 165a, 165b, respectively, and in a preferred
embodiment, two each. Vertical tube segments 165a, 165b, as with
inner tube 40, are described and depicted as hollow tubes, however,
other shapes or cross-sections may be suitable, such as a solid
rod, depending upon the design. Upper vertical tube segments 165a
have proximal end 166a, distal end 167a, surface 168a and
longitudinal axis 169a. In a preferred embodiment, vertical tube
segments 165a are formed as hollow aluminum cylinders, having an
annular cross-section, and outer diameter d8a, thickness t8a and
length n8a. In a particularly preferred embodiment, d8a is about 4
inches, t8a is about 1/2 inch, and n8a is about 98 inches, and
inner tube 40 is constructed of 6061 T6 aluminum. Tube segments
165b have similar features labeled with the suffix b, and while
upper tube segments 165a are ordinarily typical, they may differ
based upon design criteria; in addition, in a preferred embodiment,
n8b is shorter than n8b, and is about 70 inches. Also in a
preferred embodiment, axes 169a, 169b are parallel to upper and
lower boom segment axes 27a, 25a.
[0113] Remaining with FIG. 3, vertical boom section 22 preferably
also includes outer VBS panels 83, which have edges 84. Preferably,
VBS panels 83 are sufficiently wide to reach between opposing legs
145 of each of beam segments 139a and 139b, and together run the
length of vertical boom section 22. Panels 83 are mounted to legs
145, preferably using bolts 155. Panels 83 provide access to the
interior of vertical boom section 22 and protect the cabling and
other components of the instrument boom 10, and are preferably made
of about 1/8 inch aluminum sheet. Further, similarly in a preferred
embodiment, sensor packages 24 are mounted to brackets 162,
preferably by welding, which are in turn mounted to the underside
of inner legs 144 of each of beam segments 139a and 139b,
preferably using bolts 155. In a preferred embodiment, interior
face 86 of sensor packages 24 and brackets 162 substantially cover
the exterior surface of legs 144, and have a small gap located at
the junction between flanges 134e and 134f.
[0114] Vertical boom segments 26, 28 are preferably constructed in
the following fashion, using tools described above for horizontal
boom section 20. Referring to FIGS. 3 and 9, for upper boom segment
28, prior to any welding, an assembly process similar to horizontal
boom section 20 occurs. One of beam segments 139b is laid on the
flat outer surface, with inward surface 141b and legs 144, 145
facing upwardly. Proximal face 172a of VBS flange 134a is
substantially aligned to proximal end 142b of beam segment 139b,
with ears 146 extending beyond flange 134a. Side edges 137a of
flange 134a abut inward surface 141b and inner and outer legs 144,
145 congruently engage channel cuts 138a. Next, flanges 134b-134e
are similarly placed between inner and outer legs 144, 145, with
side edges 137b-137e abutting inward surface 141b and with inner
and outer legs 144, 145 congruently engaging channel cuts
138b-138e. Distal face 173e of flange 134e is substantially aligned
to distal ends 143b of beam segments 139b. Clamps may be used to
retain flanges 134 in position. Next, the second of beam segments
139b is aligned parallel to the first, with inward surfaces 141b
facing one another, and placed on top of the exposed side edges
137b-137e. This beam 139b is fitted to the flanges, side edges
137b-137e abutting inward surface 141b, and inner and outer legs
144, 145 congruently engaging channel cuts 138a-138e. The entire
assembly is then compressed, beam segments 139b pressed firmly onto
channel cuts 138a-138e; again, clamps may be used to retain flanges
134 in position. This assembly is then turned so that is rests upon
inner legs 144 and inner edges 135a-135e.
[0115] Next, remaining with FIGS. 3 and 9, one of upper tube
segments 165a is aligned with one of the set of flange holes
170a-170e, and inserted therein. Once fully inserted, proximal end
166a substantially aligns with proximal face 172a of VBS flange
134a, and distal end 167a substantially aligns with distal face
173e of VBS flange 134e. This process is repeated for the second of
tube segments 165a and flange holes 170a-170e. Next, inward
surfaces 141b of beam segments 139b are preferably tack welded, or
clamped, at several points to side edges 137a, and then similarly
for side edges 137b-137e, until inward surface 141b is abutting and
aligned to each of the opposing side edges 137a-137e. Clamping or
tack welding permits some flex, or "give" so that should there be
any need to adjust the alignment of the structure, this may more
easily be done.
[0116] Next, both of upper tube segments 165a are preferably
removed from the structure in order to permit more room for access
by a welder, and once all items are in alignment, inward surface
141b of one of beam segments 139b is welded to side edge 137a, by
applying a bead along the interface therebetween on first proximal
face 172a, then distal face 173a. This process is repeated for the
second of beam segments 139b, joining it to the second side edges
137a. This process is then repeated for side edges 137b-137e, for
both of beam segments 139b. The order in which the side edges are
joined to beam segments 139b may be altered, for instance by
joining all side edges to one beam segment first, or by starting
from VBS flange 134e, or in some other order. If upper tube
segments 165a were removed from the structure, they may be replaced
now. Then flange 134a is joined to one of upper tube segments 165a
by laying a weld bead along the interface of flange hole edge 171a
and surface 168a at one or both of proximal and distal faces 172a,
173a of flange 134a. This process is repeated for each of flanges
134b-134e, and then for the second of upper tube segments 165a. The
sequence in which the flanges are welded to tube segments may be
varied, such as by alternating tubes, and completing each flange
before continuing to the next.
[0117] Remaining with FIGS. 3 and 9, for lower boom segment 26 this
process is repeated with beam segments 139a. One of beam segments
139a is laid on the flat outer surface, with inward surface 141b
and legs 144, 145 facing upwardly, and flange 134f is set therein.
VBS flange 134f, an end cap, is substantially aligned to proximal
end 142a, with inward surface 141a abutting side edge 137f and with
inner and outer legs 144, 145 congruently engaging channel cuts
138f. VBS flanges 134f-134i are placed similarly, as in upper boom
segment 28. VBS flange 134i, an end cap, is substantially aligned
to distal end 143a. Similarly, one of lower tube segments 165b is
aligned with one of the set of flange holes 170f-170i, and inserted
therein. Once fully inserted, proximal end 166b substantially
aligns with proximal face 172f of VBS flange 134f, and distal end
167b aligns with distal face 173i of VBS flange 134i. This process
is repeated for the second of tube segments 165a and flange holes
170f-170i. A similar welding process is then carried out as in
upper boom segment 28, preferably with tube segments 165b having
been removed during welding of flanges 134.
[0118] Turning to FIG. 9, upper boom segment 28 and lower boom
segment 26 are joined at their respective distal and proximal ends,
30a, 29b, preferably by hinge 31, which is preferably located
between VBS flanges 134e, 134f, adjacent to outer edges 136e, 136f.
Hinge 31 permits a range of motion of lower boom segment 26
relative to upper boom segment 28, preferably at least about 180
degrees about hinges 31's axis of rotation 31a. This range of
motion is shown in FIG. 1D. Axis of rotation 31a preferably runs
parallel to outer edges 136e, 136f.
[0119] Turning to FIGS. 1D and 6A, the lower boom section stowage
system comprises hinge 31, cable 34, winch 35, sheaves 36a, 36b and
latches 37. Latches 37 have open and closed positions, and are also
located adjacent distal and proximal ends, 30a, 29b, preferably on
distal end 143b of beam segment 139b and proximal end 142a of beam
segment 139a, on the sides of beam segments 139a, 139b. Latches 37
are heavy duty, preferably 8,000-pound, stainless steel locking
clamps, suitable for bolting to the sides of beam segments 139a,
139b. Latches 37 also preferably have locking pins, to prevent
accidental opening of the latch. A KNU-VISE brand PC-8000-SS clamp
by Lapeer Manufacturing, Lapeer Mich., 48446 was found to be
acceptable. In a closed position, latches 37, in coordination with
hinges 31, hold flange 134f of lower boom segment 26 in a close
relationship with flange 134e of upper boom segment 28, and
maintains a rigid connection therebetween. This provides the down
position of vertical boom section 22. In an open position, latches
37 permit inner edge 135f of flange 134f to move arcuately and away
downwardly from edge 135e of flange 134e, permitting lower boom
segment 26 to rotate about axis 31a of hinges 31.
[0120] Referring to FIGS. 1D and 9, in one embodiment, hinges 31
are sets of knife hinges, one set each mounted to each side of
vertical boom section 22, at the point at which flange 134e and
flange 134f abut, and proximate to outer legs 145 of beam segments
139a, 139b. The pin in knife hinges 31 is aligned to create axis
31a, which in this embodiment, is about three inches outward of
outer legs 145. Knife hinges offer the advantage that they are
self-aligning, in axis 31a, and offer a more precise and repeatable
positioning of lower boom segment 26 relative to emitter 112. In
another embodiment, hinge 31 is at least one piano hinge, having
axis 31a, which is mounted to the outer faces of upper and lower
boom segments 28, 26, at the point at which flange 134e and flange
134f abut.
[0121] Referring to FIG. 1C, stow cable 34, used in the stowage
system, is used to raise and fold back the lower boom section, and
is preferably rigged in a double line pull configuration, in order
to reduce winch power requirements. Stow cable 34 is directed by,
and accomplishes stowage by acting at sheaves 36. Sheaves 36 are
stainless steel, V-shaped, wire cable sheaves, of about three inch
diameter. Lower sheave 36a is located near distal end 29a of lower
boom segment 26, and near outer edge 136i of VBS flange 134i, on
the outer surface of the boom segment, and is preferably set a
small distance off that surface to facilitate passage of cable 34
about sheave 36a. First and second upper sheaves 36b are located on
distal face 200 of terminal flange 198, and are also set a small
distance off that surface to facilitate passage of cable 34. The
second upper sheave 36b is set below the first, approximately 24
inches. Cable 34 should be a braided steel cable suitable for use
on a winch, and be sufficiently long to reach from proximal end 30b
sheave 36a, back to proximal end 30b, and then to winch 35 (in
FIGS. 1D and 6A). In a preferred embodiment, its length is about
fifty feet long and its diameter about 3/16 inch. One end of stow
cable 34 is fixed to the outer surface of upper vertical boom
segment 28, at a point slightly below the position of lower sheave
36a, when lower boom segment is in the stowed position. In the
stowed position, cable 34 passes downwardly, outward of boom
segments 26 and 28, and adjacent to outer panels 83, and approaches
sheave 36a from its interior side, and wraps around sheave 36a, and
is redirected upwardly from the exterior side of sheave 36b. Cable
34 then passes upwardly, outward of the above length, and
approaches second upper sheave 36b from its interior side, and
passes to the outward side of first upper sheave 36b. After being
redirected toward horizontal boom section 20, and turning to FIGS.
8A and 8B, cable 34 enters instrument boom 10 through cable chase
204 in distal face 200 of terminal flange 198. Referring to FIG.
6B, cable 34 then enters horizontal boom section 20 at distal end
46 of inner tube 40, which is open at HBS flange 66k, and, in FIG.
6D, leaves it at proximal end 44, at flange 66a. Cable 34 then
passes between upper and lower frames 207a, 207c of rear frame 207.
Cable 34 then reaches winch 35, which is mounted to the interior of
mast-head 14, and in one embodiment above, and indirectly to,
mast-head plate 97.
[0122] Referring to FIGS. 1C and 1D, with latch 37 in an open
position, winch 35 draws in cable 34, which applies an upward force
upon distal end 29a at sheave 36a, causing end 29a to swing
upwardly and outwardly on hinges 31. As end 29a swings out, cable
34 exerts an upward and inward force. Continuing, as end 29a
continues upward, outer panels 83 will reach a position
approximately level with ground 125. As cable 34 continues to be
drawn in, end 29a will approach outer panels 83 on upper boom
segment 28, and hinges 31 will approach their 180 degree extension.
Finally, in the stowed position, hinges 31 are at about 180 degree
extension, outer edge 136i of flange 134i is near upper boom
segment 28, and the outer panels of 83 of boom segment 26 are about
three inches outward of those on boom segment 28, due to the
location of axis 31a. FIG. 2B depicts the fully stowed position. In
the stowed position, lower boom segment 26 and its longitudinal
axis 25a is substantially collinear with upper boom segment 28 and
its longitudinal axis 27a.
[0123] Turning now to FIGS. 8A, 8B and 18, horizontal boom section
20 and vertical boom section 22 are preferably joined by box joint
59 and gusset assembly 61. Box joint assembly 59 is preferably
constructed as follows. Ears 146 on upper beam segment 139b extend
across the C-shaped distal ends 64 of horizontal beams 56. The
inner surfaces of ears 146 closely abut distal ends 64, which
extend beyond end cap flange 66k. Ears 146 and beams 56 are joined
by welding; in one embodiment, C-shaped distal ends 64 are welded
about at the joint with ears 146 on upper leg 58b and the side of
beams 56, and at the inner periphery of lower leg 58a. In a further
embodiment, inner edge 135a of end cap flange 134a is welded to
lower edge 72k of end cap flange 66k, but solely on the inside of
instrument boom 10. In addition, proximal ends 142b of beam
segments 139b, save for ears 146, closely abut the lower surface of
lower legs 58a and are welded thereto, preferably along the outer
periphery of inner leg 144 of beam segment 139b, and along the side
of beam segment 139b. The structure is preferably held tightly
together during the welding process, such as by using clamps and
other supports, to prevent deformation of the joints due to heat
expansion. The welds may be accomplished in various orders,
however, joining ears 146 to beams 56, one at a time, and then
joining proximal end 142b to beams 56 was acceptable. It is
important to maintain a 90-degree angle between horizontal and
vertical boom sections 20, 22, in order to obtain accurate scanning
results. Altering the order of welding to counteract results of
heat expansion may be necessary and may further depend upon ambient
environmental conditions. Exposed welds are preferably
substantially flush with the outer surfaces of beams 56 and beam
segment 139b to facilitate joining gusset assembly 61 to horizontal
and vertical boom sections 20, 22.
[0124] Remaining with FIGS. 8A, 8B and 18, gusset assembly 61
preferably includes gusset plates 147, gusset channel beam 148 and
bolts 206. Plates 147 are metal plates, preferably triangular
pieces of T6 6061 aluminum, 1/4 inch thick, having one right angle
and two sides of at least about 20 inches, and preferably about
22-26 inches, adjacent to the right angle. Gusset channel beams 148
are sections of 3'' C-channel beam about 1/4 inch thick, also
preferably T6 6061 aluminum, cut to run adjacent to the edges of
plates 147, opposite to the right angle. The long, outward face of
beams 148 abuts the outer surfaces of beams 56 and 139b. Beams 148
are preferably about 30 to about 40 inches in length, preferably
extending fully diagonally across beams 56 and beam segments 139b.
Plates 147 are located with the right angle placed at the
intersection of upper legs 58b and ears 146, and the adjacent legs
running downwardly and inwardly along the edges of outer legs 145
and upper legs 58b. Plates 147 are preferably joined to beams 56
and beam segment 139b using structural bolts 206. An acceptable
bolt pattern includes about nine along each adjacent side, about
ten along the opposite side, and five further extending from side
to side at intermediate points along each side. Beams 148 are also
preferably joined using bolts 206, six bolts each joining the beams
to beam 56 and beam segment 139b being acceptable.
[0125] Turning to FIGS. 8B and 9, preferably, a terminal flange 198
is located between ears 146 of upper beam segment 139b. Terminal
flange 198 is a further flange, in line with HBS flanges 66a-66k,
but not joined to inner tube 40 or outer tube segments 48a-48j.
Flange 198 serves primarily as a point of attachment for tension
cable distal end points 152, and to block off the open space
between the distal ends of beams 56. Turning to FIGS. 13A and 13B,
in one embodiment, flange 198 is a single plate; in another it is a
composite plate, comprised of two to about four thinner plates,
welded together face-to-face (seen in FIG. 6B). Flange 198 includes
proximal and distal faces 199 and 200, side, top and bottom edges
201, 202 and 203, tension cable chases 205 and stow cable chase
204. Turning to FIGS. 6B and 8A, tension cable chases 205 are
aligned with cable chases 80a-80k in the HBS flanges 66, and, in
FIG. 13A, have a diameter c9, while stow cable chase 204 is
slot-shaped, and aligned with distal end 46 of inner tube 40.
Flange 198 is cut to fit within the gap (see FIG. 9) created
between VBS flange 134a and ears 146, and has width w9 along top
and bottom edges 202, 203, height h9 along side edges 201, and
thickness t9 between faces 199, 200. In an embodiment using
composite plate flange 198 (see FIG. 6B), inner plates, near
proximal face 199, have a width w9 greater than those of outer
plates, near distal face 200, in order that the longer plates
overlap ears 146, and the shorter plates fit between ears 146.
[0126] Turning to FIGS. 8A, 8B and 18, two braces 214 are
preferably used to make box joint 59 more rigid, and to reinforce
terminal flange 198 where cable 150 applies tension at attachment
points 152. Each of braces 214 include forward ends 217 and rear
plates 216, and is generally "L"-shaped viewed from above, with the
long side being forward end 217. The vertical portion of forward
ends 217 abut distal face 70k of end cap flange 66k, and the bottom
side abutting end cap flange 134a, and is situated slightly
inwardly of legs 58a and 144. Rear plate 216 extends outwardly from
forward end 217, with its vertical portion abutting inward surface
60, and its bottom side notched to accommodate rear plate 216
abutting the inner surface of lower leg 58 of beam 56, and end cap
flange 134a. Rear plate 216 has 11/2 inch holes therethrough to
permit passage of the studs of cable 150, and is joined by welding
to proximal face 199 of terminal flange assembly 198, to inward
surface 60 of beams 56, and to legs 58a. Forward end 216 is welded
to end caps 134a, 66k.
[0127] Returning to FIGS. 13A and 13B, in one preferred embodiment
h9 is about 10 inches, w9 is about 15-16 inches, t9 is about one
inch, stow cable chase 204 is about 11/4 inches by about 21/2
inches, and c9 is about 11/4 inches. In another preferred
embodiment, a composite flange 198 includes four plates, each
having thickness t9 of about 1/4 inch, and having widths of 15-16
inches and about 20-22 inches. Flange 178 is preferably T6 6061
aluminum. Referring to FIG. 8A, in one embodiment, it is joined by
welding side edges 201 to the inner edges of ears 146, and bottom
edge 203 to outer edge 136 of flange 134a. Turning to FIG. 6B, in a
composite terminal flange 198, side edges 201 of narrower plates
are welded to the inner edges of ears 146, while wider plates
overlap, and are welded to the inner face of ears 146, and bottom
edge 203 is welded to outer edge 136 of flange 134a
[0128] Referring to FIG. 1C, sensor packages 24 comprise a
significant portion of the load borne by horizontal and vertical
boom sections 20, 22, and total about 1800 pounds. This weight is
roughly evenly split between the two sections, with about a 9/11
split between horizontal boom section 20 and vertical boom section
22.
[0129] In an alternative embodiment, in horizontal boom section
20', inner tube 40 and outer tube segments 48a-48j and HBS flanges
66a-66k are replaced by structures depicted in FIGS. 17A, 17B and
17C. This alternative structure can offer both advantages in weight
reduction by utilizing thinner-walled tubes in the horizontal boom
section and in construction time by utilizing a simpler
construction method. This alternative horizontal boom section 20'
utilizes several components similar to those in section 20, and
these components having the same or nearly the same components and
functions will be identified by use of a prime, thusly--'--.
Referring to FIG. 17C, horizontal boom section 20' comprises a
first support assembly, preferably treble tube assembly 230,
longitudinal and transverse axes 21a', 21b', second support
members, preferably beams 56', and a number of trilobe flanges 225,
arrayed in a spaced relationship to one another, similar to the
relationship depicted in FIG. 6A for HBS flanges 66, and as in FIG.
17C. Boom section 20' also comprises upper HBS panel 81'. In a
preferred embodiment, there are eleven trilobe flanges 225a-225k.
Referring to FIGS. 17A and 17B, flange 225a comprises trilobe
flange hole 226a, flange hole edge 227a, proximal face 68a', distal
face 70a', upper, lower and side edges 72a', 73a' and 74a', channel
cuts 75a' and cable chases 80a'. Trilobe flange hole 226a is shaped
roughly in the form of three circles of equal radius, arranged such
that their centers form an equilateral triangle having a point
facing downwardly and the opposite edge parallel to upper edge
72a'. In another embodiment, the point of the equilateral triangle
could face upwardly or otherwise. The center of the equilateral
triangle is approximately centered in flange 225a, preferably,
slightly lower than center. The circles are joined at their points
of tangency. All material is removed interior to the circles, as is
that exterior material radially inward from the three tangency
points toward the center of the equilateral triangle. Trilobe
flange hole edge 227a is defined by the convex portions of the
three circles running from one tangency point to another, the three
portions joined at the tangency points. Preferably, a small amount
of material is removed radially at the tangency points, away from
the center of the triangle, to avoid creation of very small, narrow
width flange pieces. Preferably, this material is removed about 1/4
inch from the point of tangency. Trilobe flange holes 226a is sized
to accept, preferably closely, treble tube assembly 230. Trilobe
flange 225a is constructed of aluminum plate. Flange hole 226a and
cable chases 80a' can be removed by various machining processes for
cutting thick metal pieces known to persons of skill in the art,
such as a plasma cutter, or a water jet cutter. In this embodiment,
trilobe flange 225a has height h4', thickness t4' and width w4',
and cable chases 80a have diameter c4'. In a particularly preferred
embodiment, flange 225a is constructed of 6061 T6 aluminum, h4' is
about 10 inches, t4' is about one inch, w4' is about 23 inches, c4'
is about two inches, and d4 is slightly greater than d1, about 4
1/16 inches. Trilobe flanges 225b-225k have similar features
labeled using those respective suffixes. Flange holes 226a-226k
should be aligned to an axis coincident to tube assembly axis 231.
In a particularly preferred embodiment, the spacing between the
opposing distal and proximal faces of adjacent flanges (e.g. a-b is
between distal face 70a' and proximal face 68b') is as follows: a-b
through c-d, about 15 inches; d-e, about 9 inches; e-f through j-k,
about 23 inches. Trilobe flange 225a will ordinarily be typical,
save for the varying position of cable chases 80a'-80k', but need
not be.
[0130] Turning to FIG. 17C, treble tube assembly 230 includes
longitudinal axis 231 and three tubes 232a-232c. In one embodiment,
tubes 232a, 232b are lower tubes, having longitudinal axes 234a,
234b parallel to and substantially level with one another. Upper
tube 232c has longitudinal axis 234c parallel to axes 234a, 234c,
but located between and above them. Other orientations are
possible, such as one lower tube and two upper tubes. Tubes 232a,
232b and 232c each have surfaces 233a-233c, proximal ends 236a-236c
and distal ends 237a-237c. In a preferred embodiment, tubes
232a-232c are hollow, aluminum cylinders, having circular cross
section and having length n11, outer diameter d11 and tube wall
thickness t11. In a particular preferred embodiment, d11 is about
four inches, t11 is from about 3/8 to about 1/4 inch, n11 is about
200 inches and tubes 232a-232c are constructed of 6061 T6 aluminum.
As with inner tube 40, a solid rod could be used, but a hollow tube
is advantageous. Lower tubes 232a, 232b are side by side, and have
surfaces 233a, 233b abutting one another at the tangency point.
Directly above lies tube 232c, having surface 233c abutting
surfaces 233a, 233c at tangency points on their upper sides. All
three tubes 232 have their respective ends 236 and 237
substantially aligned to one another.
[0131] The alternative horizontal boom section 20' is constructed
similarly to upper boom segment 28, using the techniques described
above. The following modifications and substitutions are preferably
made to that process. Trilobe flanges 225a-225k, tubes 232a-232c,
beams 56' and their constituents are substituted for VBS flanges
134a-134e, tube segments 165a, beam segments 139b and their
constituents, respectively. In addition, tubes 232a-232c need not
be removed from trilobe flanges 225a-225k during the welding
process, as they permit better access to the flanges. Further,
after flanges 225 are joined to treble tube assembly 230, each of
tubes 225a, 225b and 225c are preferably joined to one another by
welding longitudinally along the tangency point between surfaces
233a, 233b and 233c. Such welds are preferably not continuous, but
rather are short welds, spaced approximately one foot apart. It may
be necessary to invert the structure to accomplish this step for
the a-b interface. The sequence in which the flanges are welded to
tubes may be varied, such as by beginning at flange 225k, or by
welding the tubes together first.
* * * * *