Eccentric Rotor Mount for Induction Hardening Synchronization
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Solution Overview
Problem
Existing high-frequency induction hardening apparatuses for metal objects require numerous components and a large installation area, leading to increased production costs and maintenance challenges due to the need for precise synchronism of rotating shafts, which is difficult to maintain.
Innovation Solution
A high-frequency induction hardening apparatus with a heating coil holder and eccentric rotor mount system that allows for synchronized eccentric rotation of the heating coil with respect to the workpiece, reducing the number of components and installation area, and enabling easy maintenance by using a cam mechanism to ensure even heating across the entire surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two shafts are used to rotate heating coils eccentrically, then the workpiece surface can be heated evenly, but the synchronization between shafts is difficult to maintain and requires high precision cams
Solution Approach 1:
The patent merges the two separate shaft systems into a single shaft that simultaneously drives multiple heating coils through eccentric cams. This consolidation eliminates the synchronization problem between multiple shafts while maintaining the ability to heat different portions of the workpiece evenly. The single shaft with multiple eccentric cams ensures all heating coils rotate in perfect synchrony without requiring complex synchronization control mechanisms.
Solution Approach 2:
The single shaft serves multiple functions by simultaneously driving multiple heating coils through different eccentric cams. This multi-functional design allows one shaft to perform what previously required two separate shafts, reducing complexity while maintaining heating uniformity across the workpiece surface.
2Ease of manufacture
If multiple component parts are used for eccentric rotation mechanism, then the heating can be performed, but the production cost and installation area increase
Solution Approach 1:
The patent combines multiple heating coil mounting mechanisms into a single integrated system where one shaft with multiple eccentric cams drives all heating coils. This merging reduces the total number of components compared to having separate shafts and mounting mechanisms for each heating coil, thereby reducing production cost and installation area while maintaining the heating function.
Solution Approach 2:
The single shaft serves as a universal driving mechanism for multiple heating coils, eliminating the need for separate driving mechanisms for each coil. This multi-functional approach reduces component count and simplifies the overall structure while preserving the ability to perform heating operations.
3Reliability
If high precision cams are manufactured to ensure shaft synchronism, then the heating coil can rotate eccentrically, but the production cost and time increase
Solution Approach 1:
By merging multiple shafts into a single shaft with multiple eccentric cams, the patent eliminates the need for high precision synchronization between multiple shafts. The single shaft naturally provides perfect synchronism for all heating coils without requiring expensive high-precision cams, as there is no synchronization control to achieve.
Solution Approach 2:
The patent extracts the synchronization control problem from the system by using a single shaft instead of multiple shafts. This removes the need for high precision cams and complex synchronization mechanisms, simplifying manufacturing while maintaining reliable eccentric rotation of all heating coils.
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 apparatus achieves even heating of the workpiece surface with reduced component complexity and installation space, improving maintenance efficiency and cost-effectiveness by ensuring precise synchronization through a cam-driven system.
Implementation Method 1
high-frequency induction hardening apparatus
Implementation Method 2
heating coil for hardening a metal object
Data Source
AI summary
A high-frequency induction hardening apparatus used for metal objects, including a heating coil holder (4) carrying a heating coil (40) for hardening a metal object (2), an eccentric rotor assemble housing a cam mechanism for allowing the heating coil to eccentrically rotate through the heating coil holder (4); and a pair of supporters (11), (12) for keeping the heating coil holder (4) in a desired position, the supporters (11), (12) limiting the movement of the heating coil holder (4) to a plane intersecting the axis (21) of the cam carried in an eccentric rotor mount (13).