Induction Shrink Fitting With Recipe-Based Heating Rate Control
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Solution Overview
Problem
Existing shrink fitting techniques for aircraft engine assemblies are not practical, predictable, and cost-effective, particularly due to sensitivity to temperature and ramping rate, which hampers production efficiency and increases manufacturing costs.
Innovation Solution
An induction heating system with tooling units, a power supply, and a computer-controlled power delivery system that uses heating recipes with setpoints to precisely control the heating rate for each assembly, ensuring efficient and controlled interference fitting of male and female parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shrink fitting techniques are used to heat the female part, then the assembly can be completed, but the process is not predictable and may damage the heated part due to sensitivity to temperature and ramping rate
Solution Approach 1:
The patent applies parameter changes by implementing computer-controlled heating that precisely adjusts temperature and ramping rate parameters. The system monitors and controls the heating parameters to match specific requirements for different female parts, transforming the uncontrolled heating process into a precisely controlled one that prevents part damage while ensuring predictable shrink fitting results.
Solution Approach 2:
The patent implements feedback control through computer monitoring of the heating process. The system receives feedback on temperature and heating rate, then adjusts the power delivery accordingly to maintain optimal parameters. This closed-loop control ensures the heating process remains within safe limits while achieving the required thermal expansion for reliable shrink fitting.
2Productivity
If traditional shrink fitting techniques are used, then assembly can be completed, but production rate is reduced due to lack of optimization capability
Solution Approach 1:
The patent replaces traditional mechanical or manual heating methods with an induction heating system controlled by computer software. This substitution enables precise control over the heating process, allowing for optimized heating cycles that reduce production time while maintaining quality standards. The automated control system eliminates manual intervention, increasing productivity without proportionally increasing manufacturing complexity.
Solution Approach 2:
The patent applies preliminary action by pre-programming heating recipes and parameters in the computer control system before production begins. Different female parts have pre-defined heating profiles stored in the system, allowing operators to simply select the appropriate profile rather than manually determining heating parameters. This preparation in advance enables faster production while maintaining optimal heating conditions for each specific part type.
3Productivity
If higher temperature and faster ramping rates are used to increase production rate, then productivity improves, but the risk of damaging the female part increases
Solution Approach 1:
The patent applies dynamics by implementing a dynamic heating control system that continuously adjusts temperature and ramping rate based on real-time conditions. Rather than using fixed high parameters throughout the process, the system dynamically modifies heating intensity to match the specific requirements of each female part and stage of heating, maximizing productivity while preventing thermal damage through adaptive 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
The system enables faster, more precise, and controlled shrink fitting processes, reducing the risk of part damage and lowering manufacturing costs by optimizing the heating process for various aircraft engine assemblies.
Implementation Method 1
an induction coil configured for induction heating the corresponding female part
Implementation Method 2
induction heating the corresponding female part when in a heating position and supplied with electrical power
Implementation Method 3
heating the female part to harness the phenomenon of thermal growth
Implementation Method 4
the subsequent cooling of the female part resulting in shrinking into an interference fit with the male part
Data Source
AI summary
An induction heating system can be adapted for shrink fitting a plurality of different assemblies. A plurality of tooling units associated to respective ones of the assemblies, each one having an appropriately configured induction coil and holder, can be provided. A computer can be used to control the delivery of electrical power to the induction coil in accordance with a heating recipe, and can be provided with an input device for inputting an assembly identifier allowing the computer to operate the control based on the right heating recipe.