Pinned Fly Ring Segments Eliminate Welding

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Solution Overview

Problem

Traditional rotary drum washer fly ring manufacturing methods are labor-intensive and fail to achieve the necessary tight tolerances due to reliance on laser cutting, welding, machining, and straightening processes.

Innovation Solution

A method using high-precision laser cutting to form ring segments with lapped joints and custom fasteners, eliminating the need for welding, machining, and straightening, allowing for precise assembly by non-skilled personnel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional laser cutting, welding, machining, and straightening processes are used to manufacture fly rings, then structural integrity is maintained, but manufacturing time is excessive and labor intensity is high

Engineering Contradiction:

Improvemanufacturing timeVSAvoidlabor intensity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The fly ring is divided into multiple pre-cut segments that can be manufactured independently using laser cutting. Each segment is then assembled with adjacent segments using lapped joints and fasteners, eliminating the need for complex welding operations and significantly reducing manufacturing time and labor intensity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A lapped joint structure with fasteners is introduced as an intermediary connection method between ring segments. This intermediary mechanism replaces traditional welding and machining processes, allowing for quick assembly while maintaining structural integrity, thereby reducing both manufacturing time and labor requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If laser cutting is used to manufacture fly ring segments, then cutting speed is improved, but manufacturing precision is insufficient to meet tight tolerances

Engineering Contradiction:

Improvecutting speedVSAvoiddimensional tolerance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The ring segments are pre-cut using high-speed laser cutting with improved precision parameters. By performing the cutting operation first with enhanced accuracy, the subsequent assembly process can achieve tight overall tolerances without requiring slow, precise machining operations on each segment, thus maintaining both speed and precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The laser cutting parameters are optimized and changed to achieve both high cutting speed and improved precision. By adjusting laser power, speed, and focal position parameters, the process achieves dimensional tolerances suitable for fly ring segments while maintaining the productivity benefits of laser cutting.

Inventive Principle:

Principle #35Parameter changes

3Strength

If welding is used to join ring segments, then structural strength is achieved, but manufacturing complexity and time are increased

Engineering Contradiction:

Improvejoint strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The welding operation is extracted and removed from the manufacturing process. Instead of welding ring segments together, the design uses mechanical lapped joints with fasteners, which eliminates the complexity of weld preparation, execution, and post-weld grinding while still achieving sufficient joint strength for the application.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The connection method is simplified to use readily available fasteners and lapped joints rather than permanent welds. This approach uses simpler, more easily replaced components that reduce manufacturing process complexity and allow for easier assembly and disassembly without requiring skilled welding operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

The new method significantly reduces manufacturing time and maintains tight tolerances, enabling the production of fly rings with precise dimensions and structural integrity.

Implementation Method 1

each ring segment being laser cut

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentEP2987906B1Pinned fly ring for rotary drum washer and method of manufacture

Publication Date: 2016.12.14 OVIVO LUXEMBOURG R L

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AI summary

Disclosed is a fly ring (100) adapted to be used in a rotary drum filtering apparatus, and a method of forming such a fly ring (100). The fly ring (100) comprises a plurality of ring segments (104), each ring segment (104) being laser cut. Each ring segment (104) has a first end (108) which overlaps a second end (112) of an adjacent ring segment (104), forming a lapped joint (116). Each ring segment (104) first and second end (112) has at least two spaced apart through-holes (120, 124), the through-holes (120, 124) of the first end (108) being aligned with the through-holes (120, 124) of the second end (112). A custom fastener (130) extends through the first end (108) and second end (112) aligned through-holes (120, 124).