Functional Shaft Assembly Force Measurement
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Solution Overview
Problem
Existing methods for producing functional shafts, such as camshafts, lack efficiency and reliability in ensuring proper assembly and force distribution among functional elements, which can lead to inconsistent torque transmission and potential mechanical failures.
Innovation Solution
A method involving the insertion of functional elements with pockets into a retaining element at a predetermined angular position, with force measurement during shaft insertion, and the use of a device equipped with force measuring units, such as piezoelectric elements or strain gauges, to monitor and compare applied forces against desired values for improved assembly quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional elements are assembled manually without force measurement, then the assembly process is simple, but the reliability and consistency of torque transmission deteriorates
Solution Approach 1:
The patent implements force measurement during the assembly process to provide real-time feedback on the insertion force applied to functional elements. This feedback mechanism allows monitoring and control of assembly quality, ensuring consistent torque transmission while maintaining a relatively simple assembly device structure.
Solution Approach 2:
The patent replaces manual assembly with an automated insertion device that mechanically guides and forces functional elements into the shaft. This substitution ensures precise and consistent assembly while reducing reliance on operator skill and experience.
2Manufacturing precision
If force measurement is implemented during assembly, then the manufacturing precision and quality control improve, but the device complexity and measurement requirements increase
Solution Approach 1:
The patent incorporates force measurement with feedback capability to monitor insertion forces in real-time. This allows precise control of the assembly process while providing data for quality assurance, balancing measurement complexity with manufacturing precision requirements.
Solution Approach 2:
The measurement system is integrated into the assembly device itself, allowing the device to automatically monitor and record force data during assembly without requiring separate external measurement equipment or complex external measurement setups.
3Productivity
If multiple functional elements are assembled in one working step, then the productivity increases, but the complexity of force distribution control worsens
Solution Approach 1:
The patent combines multiple functional elements into a single assembly operation where they are inserted simultaneously or in rapid sequence into the shaft. This merging of operations increases productivity while the integrated force measurement system manages the complexity of force distribution across multiple elements.
Solution Approach 2:
The patent implements continuous force measurement throughout the assembly process, even when multiple elements are being assembled. This continuous monitoring ensures that force distribution remains controlled and consistent across all functional elements, managing complexity through uninterrupted measurement and control.
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 approach ensures reliable and efficient assembly of functional shafts by measuring and verifying the force applied during assembly, enhancing the quality of the joining process and torque transmission, thereby improving the mechanical integrity of the shaft.
Implementation Method 1
a force measuring unit (5) is provided for measuring a force that acts on the functional element (1) and/or the retaining element (4) from the shaft (3)
Implementation Method 2
force measuring units, such as piezoelectric elements or strain gauges
Data Source
AI summary
A device for producing a functional shaft and a functional shaft are provided in which a functional element which is provided with a pocket is inserted into a retaining element, a shaft is inserted into the pocket, and a force applied to the functional element while the shaft is being inserted into the pocket is measured.