Modular Ball Screw Lifting System for Vacuum Furnace
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Solution Overview
Problem
Existing lifting systems for vertical vacuum furnaces are complex, time-consuming to assemble and align, noisy, prone to synchronization issues, and can cause damage due to misalignment and over-compression of springs.
Innovation Solution
A modular lifting system using two synchronized ball screws driven by servo-type motors with encoder feedback, eliminating the need for gear boxes, shafts, and couplings, and featuring a jointed linkage to accommodate misalignment without stress, allowing for quiet operation and precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a four-point lifting apparatus with multiple gear boxes and connecting shafts is used, then the work load can be lifted evenly, but the assembly and alignment process becomes time-consuming and complex
Solution Approach 1:
The lifting system is divided into four independent lifting stations, each with its own servo motor and ball screw assembly. These modular units can be independently assembled and then easily installed at the customer site without complex alignment procedures, resolving the contradiction between reliable even lifting and assembly complexity.
Solution Approach 2:
The patent replaces the mechanical synchronization system (gear boxes, connecting shafts, couplings) with an electrical synchronization system using servo motors and controllers. This substitution eliminates the complex mechanical assembly and alignment requirements while maintaining synchronized lifting operation.
2Power
If gear boxes, drive shafts, and couplings are used in the lift mechanism, then mechanical power transmission is achieved, but considerable noise is generated during operation
Solution Approach 1:
The patent eliminates mechanical power transmission components (gear boxes, drive shafts, couplings) and replaces them with direct-drive servo motors that couple directly to the ball screws. This substitution maintains full power transmission capability while eliminating the noise generated by meshing gears and rotating shafts.
3Power
If mechanical couplings connect the drive shafts and ball screw shafts, then power transmission is maintained, but the couplings become loosened over time causing synchronization issues
Solution Approach 1:
The patent replaces mechanical couplings with electrical coupling through servo drive systems. Each servo motor is independently controlled but synchronized through electrical signals and feedback from encoders/resolvers, eliminating the mechanical wear and loosening problems of couplings while maintaining synchronization.
Solution Approach 2:
The patent incorporates encoders and/or resolvers on each servo motor to provide position feedback to the control system. This feedback mechanism enables precise synchronization of the four lifting stations without relying on mechanical linkages that can loosen over time.
4Ease of operation
If coil springs are used to contact the bottom lifting structure, then the lifting mechanism can be operated, but the springs over-compress causing bending damage to the lifting structure and door
Solution Approach 1:
The patent replaces the mechanical spring-based lifting operation with an electronically controlled servo system. The servo motors provide controlled lifting force without the over-compression problem of springs, eliminating the risk of bending damage to the lifting structure and door while maintaining ease of operation through automated 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
Significantly reduces assembly time, eliminates noise, prevents synchronization issues, and ensures precise positioning, thereby avoiding damage to the lifting mechanism and the furnace components.
Implementation Method 1
two ball screws, each driven by a servo-type motor
Implementation Method 2
synchronized with each other through an electrical servo drive system using encoders and/or resolvers to provide position feedback
Implementation Method 3
Each ball screw is constructed and arranged to lift or lower an elevator that is guided in tracks
Data Source
AI summary
A lifting apparatus for a vertical vacuum furnace is disclosed. The apparatus includes first and second support modules arranged in spaced parallel alignment and first and second reversible lifting mechanisms mounted on respective ones of the first and second support modules. The apparatus also includes first and second motive means coupled to the first and second reversible lifting mechanisms for driving the reversible lifting mechanisms. First and second trolleys are operatively connected to the first and second reversible lifting mechanisms and adapted for engaging with a payload. The apparatus further includes a control system connected to the first and second motive means for controlling the operation of the first and second reversible lifting mechanisms whereby the first and second trolleys can be raised or lowered. A vertical vacuum furnace assembly including the lifting apparatus is also disclosed as well as a support module and a bottom head assembly for the lifting apparatus.