Motor Grader Circle Assembly Additive Manufacturing
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Solution Overview
Problem
The existing circle assemblies in motor graders are expensive to manufacture due to forging processes and complex welding joints, and are prone to damage from heavy stresses during grading operations, requiring costly replacement.
Innovation Solution
A circle assembly design featuring a plate with integrally formed ring gear teeth, angled skirt portions, and a rim member with arm members and a circumferential belt, which reduces manufacturing costs and eliminates complex welding joints, while providing enhanced stress protection through a C-shaped support plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional forging processes and welding joints are used to manufacture the ring gear and circle assembly, then the structural strength and reliability are improved, but the manufacturing cost increases and the device complexity increases
Solution Approach 1:
The patent merges the ring gear and circle assembly into a single integrally formed component using additive manufacturing. The ring gear teeth are built directly onto the circle assembly body in one continuous process, eliminating the need for separate forging of the ring gear and subsequent welding operations. This integration maintains structural strength while reducing manufacturing cost and complexity.
Solution Approach 2:
The patent replaces traditional mechanical manufacturing processes (forging and welding) with additive manufacturing technology. The layer-by-layer deposition process creates complex geometries including the ring gear teeth and circle assembly in a single operation, substituting multiple costly mechanical processes with one advanced manufacturing method.
2Strength
If traditional forging and welding processes are used to manufacture the circle assembly, then the structural integrity is improved, but the manufacturing cost and time increase
Solution Approach 1:
The ring gear and circle assembly are manufactured as a single integrated component through additive manufacturing. The ring gear teeth are deposited directly onto the circle assembly body without requiring separate manufacturing steps or assembly operations, thereby reducing total manufacturing time while maintaining structural integrity.
Solution Approach 2:
The additive manufacturing process builds the entire circle assembly with integrated ring gear teeth in a single continuous operation from the beginning. This preliminary formation of the complete structure eliminates subsequent assembly steps and reduces overall manufacturing time while ensuring structural integrity throughout the component.
3Reliability
If the entire circle assembly is replaced for small damage or issues, then the reliability is maintained, but the cost and resource waste increase
Solution Approach 1:
The circle assembly is designed as a modular component that can be independently replaced without affecting other systems. The additive manufacturing process enables cost-effective production of these modular units, allowing replacement of only the damaged circle assembly rather than entire subsystems, thereby reducing resource waste while maintaining operational reliability.
4Strength
If complex welding joints are used to attach the ring gear to the diaper plate, then the structural strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The ring gear and circle assembly are merged into a single integrally formed component through additive manufacturing. The ring gear teeth are built directly onto the circle assembly body without requiring separate components or welding joints, thereby eliminating assembly complexity while maintaining joint strength through the continuous material structure.
Data Source
AI summary
A circle assembly for supporting implement of motor grader is provided. The circle assembly rotates relative to drawbar about rotation axis. The circle assembly includes plate and rim member coupled to plate. The plate defines front section and rear section and includes a ring gear portion defining a plurality of teeth formed integrally therein. A first skirt portion and a second skirt portion integrally and contiguously extend from ring gear portion at rear section. The first skirt portion and second skirt portion are angled relative to ring gear portion in direction of rotation axis. The rim member includes first arm member and second arm member attached to first skirt portion and second skirt portion, respectively, and a circumferential belt portion extending between the first arm member and the second arm member. The belt portion is spaced from and surrounds ring gear member at the front section of the plate.