Nut Feeder Air Chamber for Energy Savings
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Solution Overview
Problem
Existing nut feeders for nut resistance welding equipment require external air supply from compressors, leading to high energy consumption, complex piping, noise, and increased costs, making it difficult to save energy and reduce noise in factories.
Innovation Solution
A nut feeder design that utilizes an air chamber within a rod holder, where the volume changes with the movement of the rod, using an electric cylinder as an actuator to blow air onto the nut, eliminating the need for external air supply and incorporating an air outlet and inlet to hold the nut securely without additional stop means or sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an air pressure cylinder is used as an actuator, then the nut can be fed to the target position, but enormous amounts of electric power are consumed and air piping becomes complex
Solution Approach 1:
The invention extracts the air supply function from the external air pressure cylinder and relocates it into the rod holder, creating a self-contained air chamber that generates the necessary air pressure locally without requiring external air piping or a factory-wide air compressor system
Solution Approach 2:
The rod holder becomes self-sufficient by incorporating an air chamber that generates air pressure internally through the movement of the rod, eliminating the need for external air supply infrastructure and reducing overall system dependency on factory-wide pneumatic systems
2Productivity
If an air pressure cylinder is used as an actuator, then the nut can be fed to the target position, but noises from the air compressor deteriorate the working environment
Solution Approach 1:
The invention extracts the noise-generating air compressor from the factory environment and replaces it with a silent electric cylinder actuator, while compensating for the lost pneumatic function through an integrated air chamber that generates air pressure without mechanical noise
Solution Approach 2:
The invention replaces the mechanical pneumatic system (air compressor and piping) with an electrically-driven system (electric cylinder), substituting noisy mechanical compression with quiet electromagnetic actuation combined with internal air chamber pressure generation
3Use of energy by stationary object
If electric cylinders are used as actuators, then energy is saved and noises are reduced, but nut holding means utilizing air pressure cannot be applied
Solution Approach 1:
The invention merges the actuator function with the nut holding function by integrating an air chamber into the rod holder, combining the electric cylinder's linear motion with internal air pressure generation to simultaneously achieve both actuation and nut retention without requiring separate pneumatic components
Solution Approach 2:
The rod holder is designed with multi-functionality, serving both as the mounting structure for the electric cylinder actuator and as the container for the air chamber that provides nut holding capability, thereby eliminating the need for separate pneumatic nut holding devices
4Reliability
If air is blown to the nut to hold it on the rod, then the nut is securely held, but external air supply equipment is required
Solution Approach 1:
The invention nests the air chamber and air passage system within the rod holder structure, placing the air generation and delivery mechanism inside the existing actuator housing, thereby eliminating external air supply equipment while maintaining reliable nut holding through controlled air blowing
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 allows for energy savings, reduced noise, and lower equipment costs by eliminating the need for air compressors and piping, while maintaining effective nut holding and feeding without additional equipment, and also provides a simple mechanism for spatter removal during welding.
Implementation Method 1
the forward movement of the rod allows the air in the air chamber to be pressurized by the piston to blow the pressurized air to the nut carried on the nut holding part
Implementation Method 2
a seal for airtightly inserting a part of the rod located forward of the piston into the rod holder
Implementation Method 3
blow the pressurized air to the nut carried on the nut holding part, and then allows the nut to be fed as being held on the nut holding part by the air blow to the nut
Data Source
AI summary
The forward movement of a feed rod 15 of a nut feeder permits pressurization of air in an air chamber 3a defined in a rod holder 3, thereby blowing the air out of the air outlet 20 through an air inlet 21 and an air passage 22. A nut 7 is held on the feed rod 15 by the pressure of the air blow from the air outlet 20.