Hub Tensioning Device with Closed-Loop Force Control
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Solution Overview
Problem
The existing tensioning devices for automobile hub machining lack precision, leading to unstable tensioning forces that can cause hub loosening or elastic/plastic deformation, affecting machining quality and size precision, and often fail to ensure synchronous contact with the hub's inner hole, resulting in poor machining size.
Innovation Solution
A high-precision tensioning device comprising a stepping motor, encoder, harmonic reducer, rotary table, connecting rods, contacts, force sensors, and a slider-crank mechanism, which enables closed-loop control of tensioning force and synchronous motion of contacts, allowing for precise adjustment and stable clamping of the hub's inner hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tensioning force is increased to ensure stable clamping of the hub, then the hub can be firmly clamped and prevent loosening, but the hub will generate elastic deformation or plastic deformation, directly influencing the size precision of the hub
Solution Approach 1:
The patent employs force sensors to detect the tensioning force in real-time and feeds this information back to the control system. The controller adjusts the stepping motor's output based on this feedback to maintain the tensioning force within the optimal range, preventing both hub loosening and deformation. This closed-loop control ensures reliable clamping while protecting manufacturing precision.
2Manufacturing precision
If the tensioning force is decreased to avoid hub deformation, then the size precision of the hub is maintained, but the hub cannot be well clamped and may loosen during the machining process
Solution Approach 1:
The force sensors continuously monitor the tensioning force and provide real-time feedback to the controller. When the force drops below the threshold needed for stable clamping, the controller automatically increases the stepping motor's output to restore adequate clamping force, ensuring the hub remains securely held without causing deformation.
3Reliability
If multiple contacts are used to clamp the hub, then the hub can be securely held, but the contacts may not act synchronously on the inner hole of the hub, causing the hub to incline and resulting in poor machining size
Solution Approach 1:
The patent combines multiple contacts into a unified tensioning mechanism driven by a single stepping motor through a rotary table. This integration ensures that all contacts move synchronously and apply force evenly to the hub's inner hole, preventing hub inclination while maintaining secure holding. The mechanical linkage through the rotary table guarantees coordinated action of all contacts.
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 device achieves high-precision tensioning force adjustment and ensures synchronous contact, improving machining precision and reducing the risk of deformation, thereby meeting the stringent requirements of hub machining processes.
Implementation Method 1
an encoder (2-5) is connected to the stepping motor (2-6)
Implementation Method 2
an output end of the stepping motor (2-6) is connected with a harmonic reducer (2-7)
Implementation Method 3
the rotary table (2-2), the connecting rods (2-3), the contacts (2-4) and the circular holes of the shell (2-1) form a slider-crank mechanism
Implementation Method 4
each force sensor (2-12) is mounted in the corresponding contact (2-4), measures the size of a tensioning force
Data Source
AI summary
A high-precision tensioning device is provided. The high-precision tensioning device is composed of a stepping motor, an encoder, a harmonic reducer, a rotary table, connecting rods, contacts, force sensors, a rotary table connecting piece, a gasket, a nut, bolts, a set screw, a shell and an end cover. The tensioning device provided by the disclosure can achieve closed-loop control on a tensioning force in order to improve the tensioning precision of the tensioning device; and as long as machining and assembling errors meet design requirements, stable synchronous tensioning of three contacts can be ensured, and the location precision of a hub is improved.