Quick-Change Tool Mount With Keyed Adapter for Low Vibration
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Solution Overview
Problem
Existing methods for mounting and dismounting tools with cylindrical cavities, such as sanding or grinding wheels, on drive shafts in the metal industry are inefficient, leading to high changeover times, vibrations, and potential damage due to protruding fixing elements and mismatched diameters between drive shafts and adapters.
Innovation Solution
A mounting system featuring a drive shaft with key-zones and a collar for a spring, paired with an adapter that uses keyways and a compression spring to securely attach the tool without additional mechanical aids, allowing for precise alignment and reduced clearance, thus minimizing vibrations and enabling quick tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fixing bolt is used to secure the sanding/grinding wheel to the drive shaft, then the wheel is firmly attached, but the bolt protrudes beyond the wheel causing damage to upright sides and requiring full operator attention
Solution Approach 1:
The harmful protruding bolt is extracted from the system. Instead of using a protruding fixing element, the invention uses a set screw that engages with a transverse hole in the drive shaft, allowing the sanding/grinding wheel to be secured without any protruding elements that could damage the workpiece.
Solution Approach 2:
A set screw acts as an intermediary element between the sanding/grinding wheel and the drive shaft. The set screw engages with a transverse hole in the drive shaft and secures the wheel without protruding beyond it, mediating the connection in a way that eliminates the harmful protruding bolt while maintaining secure attachment.
2Strength
If a fixing bolt is used to secure the sanding/grinding wheel, then the wheel is firmly attached, but the changeover time for replacing wheels is relatively high
Solution Approach 1:
The drive shaft is pre-configured with a transverse hole and keyway features before the sanding/grinding wheel is mounted. The set screw is positioned to engage with this pre-prepared hole, allowing for rapid attachment and detachment of wheels without the need to loosen and remove a traditional fixing bolt, thereby reducing changeover time.
Solution Approach 2:
The attachment mechanism is segmented into separate functional elements: the transverse hole in the drive shaft, the set screw for securing, and the keyway for preventing axial movement. This segmentation allows for simpler, faster attachment and detachment operations compared to a single integrated fixing bolt system.
3Ease of manufacture
If the drive shaft diameter and adapter inner diameter are different, then manufacturing flexibility is improved, but imbalance and vibration occur resulting in cloud-like appearance on the stainless steel
Solution Approach 1:
Instead of requiring uniform diameter matching between the drive shaft and adapter throughout, the invention applies local quality by using a set screw that engages with a specific transverse hole at a particular location. This localized engagement point ensures precise positioning and eliminates vibration-induced cloud-like appearance while allowing manufacturing flexibility in the overall diameter dimensions.
4Ease of operation
If a traditional adapter with bolt is used, then the sanding/grinding wheel can be mounted, but the protruding bolt requires full operator attention to avoid damage to upright sides
Solution Approach 1:
The harmful protruding bolt is extracted from the system. The set screw engages with a transverse hole in the drive shaft and secures the sanding/grinding wheel without protruding beyond it, eliminating the need for operator attention to avoid damage to upright sides.
Solution Approach 2:
The set screw acts as an intermediary that provides secure attachment without the harmful protruding elements, simplifying operation by eliminating the need for operator vigilance regarding bolt position and potential damage to workpiece upright sides.
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 significantly reduces changeover time by up to 70%, minimizes vibrations, and allows for closer operation to vertical surfaces without damaging them, resulting in a more uniform finish and reduced risk of errors.
Implementation Method 1
a spring for introducing pressure between the drive shaft and an adapter when the drive shaft is positioned in the adapter
Implementation Method 2
each keyway having a recess for each key-zone (of the drive shaft) for allowing the drive shaft to be rotated relative to the adapter after the drive shaft is slid into the adapter
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A mounting system (100) for mounting of a tool having a cylindrical cavity (161), the system comprising a shaft (111) having a key-zone (112) and a key (113) and a collar (114) against which a spring (115) can be positioned. The system comprises an adapter (150), with a seat (155) and a keyway (151) so that the drive shaft (110) can be slid into the adapter (150) and can be rotated therein when the driving shaft (110) is slid against the spring in the adapter (150). After rotation the key is blocked behind a shoulder in the recess.