Axial Flow Element Hub Locking for Automated Flat Layer Winding
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Solution Overview
Problem
Winding operations in manufacturing processes, particularly for axial flow elements, are challenging to automate due to the need for manual attachment of materials to central mandrels, which is time-consuming and messy, especially when using adhesives or leader strips.
Innovation Solution
A pin-in-groove method is employed to secure a flat layer to a central mandrel using a locking member positioned within a groove on the mandrel's outer surface, allowing for automated attachment without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives or bonding agents are used to secure material to central mandrel, then attachment strength is improved, but manufacturing cleanliness and automation ease deteriorate due to messiness and curing time requirements
Solution Approach 1:
The patent replaces adhesive bonding (chemical system) with a mechanical interlocking system consisting of a locking member featuring barbs that engage with the wound material and a central mandrel. This mechanical system provides immediate attachment strength without requiring curing time, eliminates messiness, and enables full automation of the winding process.
Solution Approach 2:
The locking member acts as an intermediary component between the central mandrel and the wound material. It features barbs that penetrate the material and engage with the mandrel, creating a secure mechanical connection without requiring adhesives. This intermediary device resolves the contradiction by providing both strong attachment and clean, automatable manufacturing.
2Ease of operation
If manual operation is used to press material against mandrel, then ease of operation is maintained, but productivity and automation level deteriorate due to time-consuming operations
Solution Approach 1:
The locking member is designed to be self-installing during the winding process. As the material is wound onto the mandrel, the locking member automatically engages with the material and secures it in place through its barb structure. This self-service mechanism eliminates the need for separate manual pressing or bonding operations, thereby maintaining ease of operation while dramatically increasing productivity and enabling full automation.
3Reliability
If adhesives are used for securing material, then attachment reliability is improved, but manufacturing time increases due to curing requirements
Solution Approach 1:
The patent replaces adhesive bonding (which requires curing time) with an immediate mechanical interlocking system. The locking member's barbs physically penetrate and engage with the wound material and mandrel, providing reliable attachment from the moment of installation. This eliminates the curing time delay while maintaining or exceeding the reliability of adhesive bonds.
Data Source
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AI summary
An axial flow element for use in a liquid separation system for an internal combustion engine includes a hub, a groove, a locking member, and a flat layer. The hub includes a cylindrical outer surface. The groove is disposed in the outer surface. The groove extends in a substantially longitudinal direction along the hub from a first end of the hub to a second end of the hub. The locking member is disposed in the groove. The flat layer is disposed between the hub and the locking member.