Auxiliary Hub Support for Vertical Gearwheel Heat Treatment
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Solution Overview
Problem
Large gearwheels with outer diameters exceeding 400 mm experience axial run-out and conical deformation during heat treatment due to uneven cooling rates and gravitational stress, leading to undesirable deformation and potential scrapping.
Innovation Solution
A charging device comprising a charging support, a shaft, and at least one auxiliary hub that fits precisely into the workpiece's hub, allowing vertical support and stabilization, minimizing deformation by distributing load uniformly and enabling efficient heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gearwheels with outer diameters exceeding 400 mm are positioned horizontally on charging racks, then the charging process can be simplified, but axial run-out and conical deformation of gearteeth occur due to uneven cooling rates and gravitational stress
Solution Approach 1:
The patent transitions from horizontal positioning to vertical suspension of the gearwheel during heat treatment. This dimensional change allows the gearwheel to be suspended through its hub bore, eliminating contact with the charging rack and thereby preventing both axial run-out and conical deformation while maintaining operational simplicity
2Manufacturing precision
If gearwheels are positioned vertically in suspended position to prevent deformation, then manufacturing precision is improved, but the method can only be adopted if the hub diameter is sufficiently large to allow suspension
Solution Approach 1:
The patent uses auxiliary hubs that are inserted into the gearwheel's hub bore, creating a nested structure. This allows the auxiliary hubs to provide the necessary suspension points for vertical positioning, enabling the method to be applied to gearwheels with various hub diameter-to-outer-diameter ratios while maintaining manufacturing precision
3Ease of operation
If the hub diameter of the gearwheel is greater than approx. 25% of its outer diameter, then vertical suspension is possible, but oval deformation occurs during heat treatment due to gravitational stress on large diameter and weight gearwheels
Solution Approach 1:
The patent introduces auxiliary hubs with specific geometric features (such as lifting lugs or engagement surfaces) that are locally positioned to provide optimal support points. These localized structural enhancements distribute the gravitational load more uniformly, preventing oval deformation while maintaining vertical suspension capability for large diameter gearwheels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device effectively prevents axial run-out and oval deformation, ensuring dimensional stability and allowing for successful heat treatment of large gearwheels, even those with hub diameters exceeding 20% of the outer diameter, by providing uniform support and rotation capabilities.
Implementation Method 1
the medium starts boiling at the hot workpiece surfaces causing a vapor layer to build up
Implementation Method 2
the workpieces are heated in furnaces to temperatures ranging between 700° C. and 1000° C.
Implementation Method 3
the workpiece can be vertically supported on the shaft via the auxiliary hub(s) precisely fitted into the hub
Data Source
AI summary
A charging device for the heat treatment of workpieces being provided with a hub, comprising a charging support, a shaft and at least one auxiliary hub, wherein the workpiece can be vertically supported on the shaft by auxiliary hub(s) precisely fitted into the hub, and the shaft being supported by the charging support as well as use of auxiliary hubs for the dimensionally stable hardening of gear-wheels in vertical position.