Gearbox Housing Hole Realignment Through CNC Compensation Repair
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Solution Overview
Problem
Existing gearbox assemblies for rotational equipment experience wear over time, leading to deformation and misalignment of holes, which affects mechanical performance and efficiency, and replacing worn components is costly.
Innovation Solution
A gearbox repair system using a CNC system with a controller, repair tools, and a tool head to align and repair housing bodies by removing material and adding compensation vectors to restore hole positions and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gearbox components are replaced when worn, then reliability is improved, but loss of substance increases due to discarding functional components
Solution Approach 1:
The patent applies the discarding and recovering principle by removing worn or damaged material from gearbox housing components and restoring it to functional specifications through additive manufacturing. Instead of discarding entire worn housings, the system selectively removes degraded material and rebuilds affected areas (such as hole features) to original dimensions, thereby recovering the component's functionality while preserving the base structure.
Solution Approach 2:
The patent employs parameter changes by modifying the physical state and dimensions of housing material through controlled removal and additive restoration. The process transforms worn material parameters (deviated hole positions, incorrect dimensions) back to specification parameters by adjusting material volume and distribution through selective removal and deposition, thereby restoring geometric accuracy without replacing the entire component.
2Manufacturing precision
If worn gearbox components are replaced, then manufacturing precision is improved, but loss of time increases due to replacement process
Solution Approach 1:
The patent applies preliminary action by performing controlled material removal and additive restoration in a planned sequence before final assembly. The system first removes worn material to expose underlying sound material or create preparation surfaces, then applies additive material in controlled layers to restore precise hole positions and dimensions. This staged approach ensures manufacturing precision is achieved systematically, reducing rework and assembly time compared to complete component replacement.
3Manufacturing precision
If housing material is removed to repair holes, then manufacturing precision is improved, but volume of housing decreases
Solution Approach 1:
The patent applies local quality by selectively removing and restoring material only in affected areas such as hole features rather than uniformly treating the entire housing. The controlled material removal targets specific degraded zones (worn hole positions, damaged surfaces) while preserving the bulk housing structure. Subsequent additive manufacturing restores material locally to achieve precise hole positioning without significantly altering overall housing volume or structural integrity.
Data Source
AI summary
A gearbox repair system includes at least one repair tool and a controller. The controller is configured to control the at least one repair tool to repair a gearbox housing including a first housing body and a second housing body by: controlling the at least one repair tool to repair the first housing body at a first hole of the first housing body by removing a first body material of the first housing body at the first hole, controlling the at least one repair tool to identify a first actual position of the first hole, identifying a compensation vector for the first hole based on the first actual position and a first reference position for the first hole, and controlling the at least one repair tool to repair the second housing body at a second hole of the second housing body by removing a second body material at the second hole such that a second actual position of the second hole is offset from a second reference position of the second hole by the compensation vector.