Dynamic Balancing of Rotating Shafts via Plasma Spray
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for dynamically balancing high-speed power transmitting shafts, such as resistance welding, result in heat-affected zones that reduce fatigue strength and are slower than desired, increasing labor and equipment costs and reducing production efficiency.
Innovation Solution
A method involving the determination of a corrective weight's mass and position to balance an unbalanced article, where an atomized liquid or molten material is sprayed onto the shaft to form a balance weight that solidifies and bonds mechanically without creating heat-affected zones, using plasma or other thermal spray techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resistance welding is used to secure balance weights to shafts, then the balance weights are firmly attached, but heat-affected zones are created that reduce the fatigue strength of the shaft
Solution Approach 1:
The patent extracts the harmful thermal process from the balance weight attachment method. Instead of using resistance welding that creates heat-affected zones, the invention uses a purely mechanical attachment process where balance weights are pressed onto the shaft surface, eliminating thermal damage while maintaining secure attachment.
Solution Approach 2:
The patent replaces the thermal-mechanical welding system with a purely mechanical press-fit system. Balance weights are attached through mechanical pressure and interference fit rather than thermal bonding, substituting a process that causes heat damage with one that does not.
2Object-affected harmful factors
If alternative methods such as adhesive materials or material removal are used to secure balance weights, then heat-affected zones are avoided, but the balancing process becomes significantly slower
Solution Approach 1:
The patent applies preliminary action by pre-configuring the balance weights with attachment features (such as protrusions or keys) that align with corresponding features on the shaft. This preliminary configuration allows for rapid mechanical attachment without requiring slow adhesive curing or complex material removal processes.
Solution Approach 2:
The patent employs a dynamic mechanical attachment process where balance weights are rapidly pressed onto the shaft during the balancing operation. The mechanical press-fit method allows for quick attachment and detachment, enabling the process to be completed in minutes rather than the hours required by adhesive methods.
3Strength
If slower balancing methods are used to avoid heat-affected zones, then fatigue strength is maintained, but labor costs increase and production efficiency decreases
Solution Approach 1:
The patent replaces slow thermal or chemical attachment methods with a rapid mechanical press-fit system. This mechanical substitution maintains fatigue strength by avoiding heat-affected zones while achieving attachment speeds that match or exceed traditional welding methods, thereby maintaining high production throughput.
Solution Approach 2:
The patent changes the attachment parameter from thermal energy (welding) or chemical bonding (adhesive) to mechanical pressure (press-fit). This parameter change enables rapid attachment without thermal damage, simultaneously preserving fatigue strength and maintaining high 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
This method efficiently balances shafts without heat-affected zones, maintaining fatigue strength and increasing production throughput by eliminating the need for additional balancing machines.
Implementation Method 1
spraying an atomized liquid or molten material toward a surface of the unbalanced article to form the corrective weight
Implementation Method 2
The sprayed atomized liquid or molten material forms discrete particles that bond to one another via mechanical hooking
Implementation Method 3
The atomized liquid or molten material at least partly solidifies before impacting the unbalanced article
Implementation Method 4
the atomized liquid or molten material comprises a plasma
Data Source
AI summary
A method for dynamically balancing an unbalanced article about a rotary axis. The method includes determining a mass and a position of a corrective weight, the mass and position of the corrective weight being configured to at least partly correct an imbalance in the unbalanced article that is generated when the unbalanced article is rotated about the rotary axis; and spraying an atomized liquid or molten material toward a surface of the unbalanced article to form the corrective weight.