Underground Gearmotor Case Drawing Process Eliminates Welding
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Solution Overview
Problem
The existing manufacturing methods for underground gearmotor cases in automatic leaf gate systems are costly and labor-intensive, particularly due to the need for welding, which can lead to deformation and increased production costs, especially in mass production.
Innovation Solution
A metal case for gate automatic systems is manufactured using a plastic deformation method, specifically drawing, which eliminates the need for welding and reduces the number of machining operations, allowing for a single-step production of a suitable thickness case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If welding is used to join sheet metal parts for manufacturing the case, then the case can be assembled, but the heating and deformation of sheet metal occurs, resulting in deformation of interaxial distances between holes and increased manufacturing complexity
Solution Approach 1:
The patent merges multiple sheet metal parts into a single integrated case structure that is formed in one operation. The case is created as a single piece with all features (holes, flanges, walls) formed simultaneously through the drawing process, eliminating the need for welding and subsequent machining operations to join separate components.
Solution Approach 2:
The patent performs all necessary forming operations during the initial drawing process rather than requiring subsequent welding and machining steps. The case is pre-formed with all its structural features in the first operation, so no additional heat treatment or joining operations are needed that would compromise dimensional precision.
2Ease of manufacture
If multiple machining operations (cutting, bending, shaping, welding) are performed to manufacture the case, then the case can be produced, but production time and manufacturing costs increase significantly
Solution Approach 1:
The patent segments the manufacturing process into a single operation rather than multiple sequential operations. The drawing process simultaneously performs cutting, bending, shaping, and forming of all case features in one operation, dramatically reducing production time and improving mass production efficiency.
Solution Approach 2:
The patent combines multiple machining operations into a single drawing operation. All case features including walls, holes, flanges, and mounting surfaces are formed simultaneously in one operation, eliminating the need for separate cutting, bending, shaping, and welding steps.
3Ease of manufacture
If conventional manufacturing methods are used for mass production, then cases can be manufactured, but the costs are extremely high due to multiple machining operations and welding requirements
Solution Approach 1:
The patent merges all case features into a single integrated structure that is formed in one drawing operation. This eliminates the need for multiple separate machining operations and welding processes, significantly reducing material waste, energy consumption, and manufacturing costs for mass production.
Solution Approach 2:
The patent performs all necessary forming operations during the initial drawing process rather than requiring subsequent welding and machining steps. This preliminary formation of all features in one operation eliminates costly post-processing operations and reduces overall production expenses.
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 significantly reduces production costs and eliminates the drawbacks of welding, enabling efficient and cost-effective mass production of metal cases for underground gearmotors while maintaining structural integrity.
Implementation Method 1
subjecting a metal sheet to plastic deformation, in particular drawing
Implementation Method 2
Deformation is performed by means of a punch, which pushes the metal sheet, which may be fixed with a sheet clamp, inside a die
Data Source
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AI summary
A foundation and containing case for gate automatic systems is described, said case being designed to be buried underground and to house a gearmotor for displacing a leaf of the gate and being obtained by means of a method involving drawing as one piece and comprising an opening having an edge which is flared outwards and defines internally a step for receiving and supporting a cover.