Forged Fan Clutch Wrench Rod With Integral Wing-Plate Head
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Solution Overview
Problem
The existing wrench assemblies for disassembling fan clutches are structurally weak and require numerous manufacturing steps, making them inefficient and difficult to use in confined spaces with foreign objects, especially when trying to loosen nuts.
Innovation Solution
A method for manufacturing an operation rod through forging, which includes preparing a rod material, fixing it on a forging mold, and performing a forging process to create a semi-finished head with specific structures, followed by a cutout process to form a head portion with wing plates and a shaft, enhancing structural strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional manufacturing methods are used for the operation rod, then the manufacturing process requires many procedures, but the productivity is low and the structure strength is insufficient
Solution Approach 1:
The patent combines multiple manufacturing operations into a single forging process. The forging mold integrates multiple cavities that simultaneously form the head portion with wing plates and shaft, eliminating the need for separate machining operations and assembly steps, thereby improving both productivity and structural integrity
Solution Approach 2:
The forging process pre-forms the complex geometry of the head portion including wing plates and shaft in a single operation. The mold cavities are designed to create the final near-net shape with proper grain structure, eliminating subsequent machining and assembly operations that would compromise structural strength
2Ease of manufacture
If the operation rod structure is simplified for easy manufacturing, then the manufacturing process becomes easier, but the durability and structure strength become insufficient
Solution Approach 1:
The complex multi-component structure (head, wing plates, shaft) is merged into a single forged component. The integrated design eliminates weak points from assembly joints while the forging process ensures uniform grain structure throughout, simultaneously achieving manufacturing simplicity and enhanced durability
Solution Approach 2:
The forging process creates a composite microstructure within the single piece operation rod, with optimized grain flow patterns that follow the contours of the wing plates and shaft, providing superior mechanical properties and durability compared to assembled components
3Strength
If the operation rod is made with complex structure for high strength, then the structure strength is improved, but the manufacturing process requires many procedures reducing productivity
Solution Approach 1:
The complex geometry required for high strength (wing plates, shaft, interconnections) is pre-formed in the forging mold cavities. The mold design incorporates all structural features in a single operation, creating the near-net shape that requires minimal post-processing while maintaining high structural integrity
Solution Approach 2:
Multiple structural elements that would traditionally require separate manufacturing and assembly operations are merged into a single forging process. The integrated mold system simultaneously forms the head portion, wing plates, and shaft connections in one operation, reducing manufacturing complexity while preserving structural strength
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 forged operation rod provides improved structural strength and durability, simplifying the manufacturing process and enhancing the wrench assembly's ability to effectively disassemble fan clutches, even in challenging environments with foreign objects.
Implementation Method 1
carrying out a forging process, making the forging mold impact and press the head portion along a processing direction to produce a semi-finished head
Data Source
AI summary
A method for manufacturing an operation rod of a wrench assembly for disassembling a fan clutch, including following steps of: preparing a rod material; fixing the rod material on a forging mold; carrying out a forging process to produce a semi-finished head; carrying out a cutout process, cutting the remainder structure out of the semi-finished head; obtaining a finished product of a head portion, the head portion including two wing plates and a shaft which are integrally formed.