Disc Blade Balancing Using Eccentric Drilled Holes
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Solution Overview
Problem
The existing manual balancing process of disc blades is time-consuming, costly, and prone to human errors, leading to potential mechanical weakness and rejection of disc blades.
Innovation Solution
A method and machine for automatically balancing disc blades by creating one or more transversal holes in an eccentric position relative to the central axis, using a drilling assembly controlled by an electronic control device to precisely calculate and remove material for balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual balancing process is used, then skilled operators can perform the balancing, but the process requires a lot of time and has very high costs
Solution Approach 1:
The system performs automatic balancing without requiring skilled operators. The control unit automatically controls the drilling device to create balancing holes based on data from the unbalance detection device, making the system self-sufficient and eliminating dependency on operator expertise while maintaining high productivity
Solution Approach 2:
The patent replaces the manual mechanical grinding process with an automated drilling system. The drilling device creates balancing holes through the disc blade based on electronic control, substituting the mechanical grinding operation with a more precise and faster drilling operation that is automatically controlled
2Manufacturing precision
If manual grinding is used to remove material, then the center of mass can be adjusted, but the operator may accidentally remove too much material, jeopardizing mechanical resistance
Solution Approach 1:
The system uses an unbalance detection device to measure the disc blade's unbalance characteristics, and the control unit processes this feedback data to determine the precise location and dimensions of balancing holes. This closed-loop feedback system ensures that material is removed only where needed and in the exact quantity required, preventing over-removal and protecting tooth strength
Solution Approach 2:
The control unit calculates and determines the optimal balancing hole parameters before drilling begins. The system performs preliminary analysis of the unbalance data and pre-determines the drilling parameters, ensuring that the actual drilling operation removes the precise amount of material needed without risking excessive material removal
3Manufacturing precision
If repeated balancing cycles are performed, then the correct balancing can be reached, but the process requires a lot of time
Solution Approach 1:
The control unit performs preliminary calculation and determination of the optimal balancing hole parameters (location, diameter, depth) based on the unbalance detection data. This pre-planning eliminates the need for repeated trial-and-error cycles, as the system determines the complete balancing solution in advance and executes it in a single operation
Solution Approach 2:
The automated system performs the complete balancing operation in one cycle without requiring repeated manual interventions. The control unit automatically processes the unbalance data, determines the drilling parameters, and executes the drilling operation, eliminating the time-consuming repeated cycles characteristic of manual balancing processes
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 automatic balancing method significantly reduces the time and cost associated with the process, minimizes production waste, and ensures precise balancing without the need for skilled operators, thereby enhancing the efficiency and reliability of disc blade production.
Implementation Method 1
making, in the central disc, one or more transversal holes, in an eccentric position with respect to the rotation axis, by means of a drilling assembly
Data Source
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AI summary
A method for balancing disc blades (100) comprising the steps of: determining the initial position of the center of mass of the disc blade (100) to be balanced with respect to its main axis (A); calculating/determining the number, the position and/or the dimensions of one or more balancing holes (109) eccentric with respect to said main axis (A) and necessary for removing an amount of material sufficient to bring the center of mass of the disc blade (100) at a distance from the main axis (A) lower than a predetermined maximum limit value; and forming said balancing hole or holes (109) on the central disc (101) in an eccentric position with respect to said main axis (A).