Integrally Machined High-Frequency Heat Treatment Coil for CVJ
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Solution Overview
Problem
The existing high-frequency heat treatment coils for constant velocity universal joints face challenges in achieving high dimension accuracy and preventing cracking due to self-heating, requiring skilled brazing and long assembly times, and often result in complex coil shapes that disrupt electrical matching and reduce coil life.
Innovation Solution
The high-frequency heat treatment coil is formed by machining an integrated heating section and joining cover members outside the heating section, reducing deformation and distortion, and minimizing current concentration at potential breakage points, thereby maintaining high accuracy and extending coil life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple components are brazed together to form the heating section, then the coil can be assembled with flexible design, but the assembly time increases and dimension accuracy deteriorates due to deformation and distortion from brazing
Solution Approach 1:
The patent merges multiple brazed components into a single integrally machined heating section. Instead of assembling multiple copper components through brazing, the invention machines the heating section as one unified piece, eliminating brazing joints and their associated dimensional inaccuracies while maintaining manufacturing flexibility through machining processes.
Solution Approach 2:
The patent segments the coil into two functional zones: the heating section (integrally machined for high precision) and the non-heating section (where cover members are joined outside the heating zone). This segmentation allows different manufacturing approaches for different functional requirements, achieving both precision where needed and assembly flexibility where appropriate.
2Ease of manufacture
If brazing is used to assemble the coil components, then the coil can be constructed with multiple functional sections, but skilled brazing is required and assembly time increases
Solution Approach 1:
The patent combines multiple brazed components into a single integrally machined heating section, eliminating the need for skilled brazing operations. This reduces assembly complexity and time while maintaining the capability to construct coils with different configurations through machining variations rather than assembly variations.
Solution Approach 2:
The patent replaces the brazing process (a thermal-chemical joining method requiring skill and time) with mechanical machining processes. The heating section is machined directly from material, substituting a complex assembly process with a more efficient manufacturing process that does not require specialized brazing skills.
3Adaptability or versatility
If the coil shape is made complex to accommodate multiple heating sections, then the coil can be fitted to specific product shapes, but electrical matching is disrupted and coil life is reduced
Solution Approach 1:
The patent applies local quality by concentrating the heating function in specific localized zones (heating sections) while keeping other areas (non-heating sections) simple and free of current concentration. The integrally machined design allows precise control of local geometry to achieve adaptability without compromising overall reliability, as current paths are optimized to avoid concentration at complex joints or transitions.
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 allows for high-quality heat treatment with reduced self-heating, preventing cracking, and enhancing assembly efficiency, resulting in a stable and long-lasting coil that maintains high-frequency quenching and tempering performance.
Implementation Method 1
high-frequency heat treatment coil including a heating section for heating a heat treatment portion of an outer joint member
Implementation Method 2
a coil suitable for each product in terms of a product shape, quenching depth, a quenching range, and the like is to be used
Data Source
AI summary
A method is provided to produce a high-frequency heat treatment coil including a heating section for heating a heat treatment portion of an outer joint member for a constant velocity universal joint. The heating section is formed by machining in an integrated manner, and is joined to another section to complete the high-frequency heat treatment coil.