Modular Workpiece Support Structure for Thermal Processing Wear
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Solution Overview
Problem
Existing workpiece support members for thermal processing machines require full replacement when damaged, leading to increased production costs and labor, as well as potential issues with rattling and deformation due to repeated use.
Innovation Solution
A workpiece support member with a base member and removable supporting members made of carbon fiber, where the supporting members are attached via protruding attachment parts and can be easily swapped out when damaged, utilizing the elasticity of carbon fiber to prevent rattling and simplify production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If workpiece support members are made as single integrated members, then structural strength and stability are improved, but replacement cost and labor increase when damage occurs
Solution Approach 1:
The workpiece support member is divided into two separate parts: a base member and a supporting member. The supporting member that contacts the workpiece can be detached and replaced independently from the base member, allowing only the damaged portion to be replaced rather than the entire integrated structure.
Solution Approach 2:
The supporting member is designed as a replaceable component that can be discarded when damaged and recovered/reused the base member. This allows selective replacement of only the consumable supporting member while retaining the reusable base member, reducing overall replacement costs.
2Reliability
If workpiece support members are replaced frequently due to thermal processing damage, then workpiece quality is maintained, but production cost and downtime increase
Solution Approach 1:
By segmenting the support member into replaceable supporting members and a reusable base member, the system allows quick replacement of only the damaged supporting members during thermal processing, minimizing downtime while maintaining workpiece quality.
Solution Approach 2:
Multiple supporting members are prepared in advance and can be quickly swapped during processing. This preliminary preparation allows for rapid replacement without extensive setup time, reducing production downtime.
3Stability of the object's composition
If supporting members are made from carbon fiber with elastic properties, then rattling and deformation are prevented, but manufacturing complexity increases
Solution Approach 1:
The supporting member is made from carbon fiber, a composite material that provides both the necessary mechanical strength and elastic properties to prevent rattling and deformation during thermal processing, while allowing for lightweight construction.
Solution Approach 2:
The elastic properties of carbon fiber are utilized to change the mechanical behavior of the supporting member, allowing it to flex slightly and absorb vibrations rather than rigidly resisting them, thereby preventing rattling and deformation.
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
Enables efficient and cost-effective replacement of damaged supporting members, reducing production costs and maintaining a stable support structure, while preventing molten metal adherence and ensuring secure attachment.
Implementation Method 1
a supporting member formed of a plate-like member of a carbon fiber
Data Source
Figure 1
Figure 2~2(b)
Figure 3~3(b)
AI summary
A workpiece support member for a thermal processing machine is installed on a workpiece support table to support a workpiece to be thermally processed, and includes a base member and a supporting member. The base member is formed of a plate-like member in a horizontally long shape, and provided with a plurality of protruding supporting member attachment parts at predetermined distance intervals on an upper part thereof. The supporting member is formed of a plate-like member in a horizontally long shape, and is installed in an attachable and removable state with a lower side thereof fitted alternately to a front surface and a rear surface of each of the adjacent supporting member attachment parts of the base member.