Concave Bimetal Disc Assembly Without Notch Stress
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Solution Overview
Problem
Conventional bimetal strip switches face issues with accuracy and structural integrity due to notch-based positioning methods, leading to increased defect rates and reduced service life, as well as instability in over-current tripping and curvature deformation.
Innovation Solution
A method involving a concave disc-shaped bimetal strip structure with displaceable positioning holes on guiding pins, allowing for precise riveting and bonding without external notches, which maintains internal stress and improves accuracy and service life by using a compression module to narrow positioning holes and assembling holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If notch-based positioning method is used to condense bimetal strip, then positioning can be achieved, but manufacturing precision and structural integrity deteriorate due to defects and stress concentration
Solution Approach 1:
The invention extracts and removes the notch structure from the bimetal strip, replacing it with a hole-based positioning system. The positioning holes are formed by punching through the bimetal strip and are配合 with positioning pins in the fixture, eliminating the need for notches and their associated stress concentration and manufacturing defects.
Solution Approach 2:
The invention introduces positioning pins as an intermediary element between the bimetal strip and the fixture. These pins insert into the positioning holes to achieve precise positioning during the condensing process, providing a more reliable and accurate positioning mechanism compared to the direct notch-based method.
2Ease of manufacture
If notch-based positioning method is used, then positioning can be achieved, but service life reduces due to structural weakness at notch locations
Solution Approach 1:
The invention removes the notches from the bimetal strip structure, eliminating the stress concentration points that lead to structural weakness and reduced service life. The hole-based positioning system maintains positioning functionality while preserving the structural integrity of the bimetal strip.
3Shape
If conventional pressing method is used to form disc-shaped structure, then shaping can be achieved, but internal stress distribution deteriorates leading to unstable tripping characteristics
Solution Approach 1:
The invention performs preliminary positioning of the bimetal strip using positioning holes and pins before the actual condensing process. This preliminary action ensures correct alignment and positioning, allowing the subsequent pressing to proceed uniformly and achieve stable internal stress distribution without the need for notches or complex positioning mechanisms.
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
This approach reduces over-current tripping errors, enhances structural integrity, and allows for accurate overload current calculation, improving product reliability and reducing defect rates.
Implementation Method 1
The bimetal strip is a composite material composed of two or more metals or other materials with suitable properties, bimetal strip is also known as thermal bimetal strip, two strips have two different expand rates. when they are heated, the different expansions force the flat strip to bend one way.
Implementation Method 2
the guiding surface is used to condense during pressing down so that the assembling hole at the outer edge can be inserted into the rivet to be riveted and combined for positioning
Data Source
AI summary
A manufacture method of a concave disc-shaped structure of bimetal strip, particularly to one that is a coaxial positioning method of the guide hole which having elastic disc-shape structure bimetal strips not affected by external stress, which having a bimetal structure which outer edge will not be damaged and does not affect by stress while inner edge pulling closed to the outer edge, it includes: a bimetal strip, a lug, and an assembling jig, having two displaceable positioning holes, and use the guiding surface to make the two positioning holes gradually turn inside to condense to the combining surface of the lugs, so as to achieve the purpose of accurate positioning and combination.