Compact Worm-Gear Force Mechanism for Space-Limited Mold Adjustment
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Solution Overview
Problem
Existing force applying devices in compact form factors are limited in their ability to efficiently apply forces between two objects in a manner that minimizes space usage, particularly in applications like direct chill casting where thermal stresses and deformations lead to inefficiencies and waste due to the need for larger devices to accommodate force application.
Innovation Solution
A compact gearbox system with worm gears, threaded shafts, and attachment plates that apply equal and opposite forces to dynamically adjust the shape of mold sidewalls during the casting process, allowing for closer placement of mold assemblies and reducing waste by minimizing the space required for force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If larger force applying devices are used to apply forces between objects, then the force application capacity is improved, but the space required for device placement increases
Solution Approach 1:
The first threaded shaft is received within the cavity of the second threaded shaft, creating a nested configuration. This nesting allows the force applying device to maintain high force capacity through the threaded shaft mechanism while significantly reducing the overall space required for device placement, as the shafts occupy the same spatial envelope rather than requiring separate volumes.
Solution Approach 2:
The invention transitions from a conventional side-by-side arrangement of mechanical components to a nested configuration where the first threaded shaft is positioned within the cavity of the second threaded shaft. This dimensional reorganization allows the force applying device to achieve high force capacity without proportionally increasing the space required for placement.
2Force
If larger force applying devices are used to accommodate force application needs, then the force application capacity is improved, but the device complexity increases
Solution Approach 1:
The invention merges multiple functional elements into a unified nested structure where the first threaded shaft and second threaded shaft share the same spatial envelope. This consolidation achieves the required force application capacity through coordinated action of the nested shafts while reducing device complexity by eliminating the need for separate, larger mechanical assemblies.
3Force
If more space is allocated for force application devices, then the force application effectiveness is improved, but the casting pit utilization decreases
Solution Approach 1:
The nested configuration of the threaded shafts enables the force applying device to deliver effective force application while occupying minimal space within the casting pit. This space efficiency directly improves casting pit utilization by allowing closer placement of mold assemblies, thereby increasing the number of molds that can be accommodated in a given pit volume.
Solution Approach 2:
By reorganizing the force applying mechanism into a nested dimensional arrangement rather than a conventional extended configuration, the invention achieves effective force application with reduced spatial footprint, thereby improving casting pit utilization and productivity.
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 compact force applying device enables efficient casting by reducing the space needed between mold assemblies, improving casting pit utilization, and minimizing waste by applying forces that dynamically adjust the mold sidewalls, thereby enhancing the overall efficiency of the direct chill casting process.
Implementation Method 1
a worm gear; a worm wheel gear engaged with the worm gear
Implementation Method 2
a first threaded shaft received by the first threaded hole; and a second threaded shaft received by the second threaded hole
Data Source
AI summary
The present invention relates to a system and apparatus for application of force in a compact form factor. An apparatus for application of force includes: a worm gear; a worm wheel gear engaged with the worm gear; a gear shaft coaxial to the worm gear and rotatably coupled to the worm wheel gear; a first threaded hole proximate a first end of the gear shaft; a second threaded hole proximate a second end of the gear shaft opposite the first end; a first threaded shaft received by the first threaded hole; and a second threaded shaft received by the second threaded hole, where the first threaded shaft and the second threaded shaft are configured to advance toward one another and away from one another responsive to rotation of the worm gear.