Electron Beam Welded Rotational Measurement Scale
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Solution Overview
Problem
Existing angle measuring systems for high-speed machine spindles face mechanical loads and centrifugal forces, requiring materials with high fatigue strength and durability to ensure safety and accuracy at extreme speeds.
Innovation Solution
A method involving electron beam welding of a hard-magnetic second component with an angle scale, where the weld seam is axially extensive and the components are monolithic, allowing for high-speed operation and economic production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional soldered connections are used to join scale components, then manufacturing is easier and more economical, but the fatigue strength and mechanical durability are insufficient for extremely high speeds
Solution Approach 1:
The patent merges multiple components (first component, second component with angle scale, and third component) into a single welded assembly, replacing traditional soldered connections with electron beam welding to achieve monolithic construction that withstands high-speed centrifugal forces
Solution Approach 2:
The patent changes the joining method from soldering to electron beam welding, and increases the weld seam depth parameter to at least 50% of axial extent, transforming the connection strength to accommodate extremely high rotational speeds
2Speed
If monolithic components are used to increase permissible maximum speed, then fatigue strength improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the scale into multiple separable components (first component, second component with angle scale, third component) that are subsequently welded together, allowing manufacturing of individual parts followed by assembly through electron beam welding to achieve monolithic strength
Solution Approach 2:
The patent transitions from two-dimensional surface welding to three-dimensional deep penetration welding with axial depth of at least 50%, creating a volumetric monolithic structure that enables high-speed operation while maintaining component separability for manufacturing
3Reliability
If deep penetration electron beam welding is used to create extensive weld seams, then mechanical durability improves, but manufacturing complexity increases
Solution Approach 1:
The patent specifies precise welding parameters including electron beam energy, weld seam depth of at least 50% axial extent, and circumferential positioning, transforming the welding process into a controlled, repeatable manufacturing step that ensures mechanical durability
Solution Approach 2:
The patent prepares components with predetermined geometries and positioning features before welding, allowing the electron beam welding process to be performed with precise control and repeatability, reducing manufacturing complexity through pre-planning
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 solution enables the creation of a material measure suitable for extremely high speeds, enhancing fatigue strength and mechanical durability, thus addressing safety and performance concerns in high-speed spindle applications.
Implementation Method 1
welding the components using an electron beam welding process
Implementation Method 2
welding the components using an electron beam welding process, the weld seam, which is produced by the electron beam welding process
Implementation Method 3
the angle scaling is applied by a magnetization process, so that the angle scaling then consists of differently magnetized areas
Data Source
Figure 1a~2
Figure 3
AI summary
Measuring scale for measuring the rotational position of a machine part around an axis (Z), comprises a first component (1) and a second component (2) with an angle scaling (Sc). The components are welded by an electron beam welding process. An independent claim is also included for producing the measuring scale for measuring the rotational position of a machine part around an axis, comprising providing a first component and a second component; welding the components by the electron beam welding process; and applying an angle scaling to the second component.