Magnetic Feeding Rod Alignment for Flanged Shaft Insertion
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Solution Overview
Problem
Existing feeding rods for shaft-shaped components with integrated circular flanges and shafts face challenges in accurately inserting the components into receiving holes due to inclination and potential deviations caused by wear, vibrations, and misalignment, leading to issues with eccentricity and uneven welding.
Innovation Solution
The feeding rod is designed with an inclined advance and retreat axis, a permanent or electromagnet for close contact with the flange, and a positioning protrusion to set the relative position, ensuring the shaft portion enters the receiving hole accurately by initiating an arc movement that aligns the central axis vertically, even with small diameter differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inner diameter of the receiving hole is made larger with respect to the diameter of the shaft portion, then the shaft-shaped component can be inserted even with runout displacement or vibration, but the eccentric amount of the shaft portion in the receiving hole increases and the central axis of the shaft-shaped component is significantly displaced from the central axis of the receiving hole
Solution Approach 1:
A guide member is introduced as an intermediary component between the shaft-shaped component and the receiving hole. The guide member has a guide hole with an inner diameter larger than the shaft portion diameter, allowing the shaft to pass through while the guide member itself maintains precise positioning. This mediator absorbs the runout and vibration effects, preventing direct transmission to the shaft-receiving hole interface.
Solution Approach 2:
The positioning function is segmented into two stages: first, the guide member positions the shaft-shaped component during insertion; second, the shaft portion is inserted into the receiving hole with precise positioning. This segmentation allows the guide hole to have a larger diameter for tolerance accommodation while the final positioning is achieved through the guide member's precise geometry.
2Duration of action of stationary object
If the feeding rod is supported by a bearing structure to enable advance and retreat, then the feeding rod can be reused, but the tip position fluctuates due to wear of bearing sliding portion and changes in oil film thickness
Solution Approach 1:
The mechanical bearing support system is replaced with a guide member that provides both support and precise positioning. The guide member slides within the guide hole, providing a wear-resistant interface that maintains tip position precision over extended service life without the degradation issues of traditional bearing structures.
Solution Approach 2:
The guide member is designed to absorb and compensate for wear and dimensional changes over time. By providing a predetermined clearance and friction-based positioning mechanism, the system maintains accurate tip positioning even as the guide member experiences wear during operation.
3Adaptability or versatility
If vibrations from peripheral devices act on the feeding rod, then the system can operate with standard peripheral equipment, but the tip position deviates causing inaccurate insertion
Solution Approach 1:
The guide member acts as a vibration-isolating intermediary between the feeding rod and the shaft-shaped component. It absorbs vibrational energy through controlled friction and elastic deformation, preventing vibration transmission to the insertion interface while allowing the system to operate with standard peripheral devices.
Solution Approach 2:
The guide hole inner diameter is set to a specific parameter range (larger than shaft portion diameter) that provides optimal balance between vibration absorption and positioning accuracy. This parameter optimization allows the system to tolerate vibrations from peripheral devices while maintaining insertion precision.
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 solution ensures secure and accurate insertion of the shaft portion into the receiving hole, minimizing displacement and maintaining precise relative positioning, even with fluctuations or runout displacements, and allows for reliable operation despite potential stop position variations.
Implementation Method 1
a surface of the flange is held by the feeding rod in close contact with a tip surface of the feeding rod by an attraction force of an advancing and retreating permanent magnet or electromagnet disposed in the feeding rod
Data Source
AI summary
A feeding rod is configured to insert a shaft-shaped component having a circular flange and a shaft portion into a receiving hole. A central axis of the shaft portion is disposed in an inclined state with respect to a central axis of the receiving hole due to the inclined disposition of the feeding rod. A surface of the flange is in close contact with a tip surface of the feeding rod due to an attraction force of a magnet of the feeding rod. A positioning protrusion receives an outer peripheral portion of the flange and sets a relative position between the feeding rod and the shaft-shaped component. A most advanced stop position of the feeding rod is a position where a tip portion of the shaft portion has entered the receiving hole, and the attraction force of the magnet is configured to be eliminated at the stop position.