Balancing Machine Demagnetizing Device for Shaft Welding
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Solution Overview
Problem
Balancing machines often magnetize ferromagnetic workpieces during the resistance welding process, necessitating measures to prevent magnetization and demagnetize the workpieces afterwards, which complicates the balancing process.
Innovation Solution
Incorporating a demagnetizing device with a ring or U-shaped coil connected to an AC power source, arranged near the bearing stands, allowing coordinated movement with the welding device to ensure effective demagnetization without interference, and capable of reaching the entire length of long workpieces like shafts and cardan shafts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a resistance welding process is used to attach balancing masses to ferromagnetic workpieces, then the balancing precision is improved, but the workpiece becomes magnetized which is harmful for its intended use
Solution Approach 1:
The patent converts the harmful magnetization effect into a beneficial demagnetization process by introducing a demagnetizing device with AC-powered coils. The device generates alternating magnetic fields that progressively reduce the workpiece magnetization to zero, effectively eliminating the harmful effect while preserving the beneficial welding process for balancing correction
Solution Approach 2:
The demagnetizing device is positioned to demagnetize the workpiece after welding but before the workpiece leaves the balancing machine. This preliminary action ensures that the workpiece is demagnetized in advance before being transferred to the next production stage, preventing magnetization-related issues in subsequent operations
2Object-generated harmful factors
If a demagnetizing device is added to the balancing machine, then the magnetization problem is solved, but the device complexity increases
Solution Approach 1:
The demagnetizing device is integrated into the existing balancing machine structure by utilizing the available space around the workpiece holding area. The coils are positioned to encompass the workpiece without requiring separate dedicated space, and the control system is merged with the existing machine control architecture, reducing overall system complexity
Solution Approach 2:
The demagnetizing device is designed to handle various types of ferromagnetic workpieces (shafts, cardan shafts, axles) with different lengths and geometries. The AC-powered coil system can demagnetize diverse workpiece types using the same basic mechanism, eliminating the need for multiple specialized demagnetizing devices
3Manufacturing precision
If the demagnetizing device is positioned to cover the entire workpiece length, then the demagnetization effectiveness is improved, but the device size and cost increase
Solution Approach 1:
The demagnetizing device incorporates a movable carriage system that allows the AC-powered coils to travel along the length of long workpieces such as cardan shafts. This dynamic positioning enables complete coverage of extended workpieces without requiring excessively large fixed coil structures, optimizing both demagnetization effectiveness and manufacturing cost
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 solution effectively reduces magnetization of balanced workpieces, allowing for efficient demagnetization in parallel with the balancing process, reducing cycle time and enhancing demagnetization coverage, while being cost-effective and easy to integrate into existing machines.
Implementation Method 1
The demagnetizing device has a coil (131) which can be connected to an AC power source and is designed in the shape of a ring or U-shaped workpiece
Implementation Method 2
The demagnetizing device is arranged in the area of the at least one bearing stand (3, 4) and can be moved by means of a drive device (119) from the area of the at least one bearing stand (3, 4) to the area of the balancing machine (101) in which an imbalance is compensated for on the workpiece (W)
Implementation Method 3
a welding device (109) which compensates for the imbalance on the workpiece (W) with the aid of an electric welding process, in particular a resistance welding process
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The machine (1) has supporting stands (3, 4) for rotatably supporting work pieces i.e. shafts (W), to be balanced, and an axis of rotation provided for the supporting stands. Demagnetizing devices (13, 14) demagnetize the work pieces and have coils (131, 141) attached to a current source. The demagnetizing devices are arranged in an area of the supporting stands and movable in an area of the machine using a linear drive such that imbalance of the work pieces is compensated using a resistance welding process. The demagnetizing devices are movable along the axis by a straight guide.