Planetary Reform Roller for Fast Vessel Cavity Reshaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for reforming casting vessels and other plastically deformable objects like pipes and tanks are costly and time-consuming, requiring hot reforming processes that result in significant production downtime.
Innovation Solution
A device comprising a central shaft, roller gears, and rollers with specific shapes and surfaces is used to progressively reform vessel cavities by rotating and moving through the cavity, utilizing gear reduction and translation mechanisms for efficient deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot reforming process is used to reform casting vessels, then the vessel cavity can be reshaped, but the production downtime becomes very long (up to twelve hours)
Solution Approach 1:
The patent replaces the traditional thermal-mechanical reforming system with a purely mechanical roller-based system. Instead of using heat and hydraulic pressure to slowly push walls outward, the invention uses rotating rollers with specific surface profiles to mechanically reshape the vessel cavity at room temperature, dramatically reducing reforming time from twelve hours to a fraction of that time.
Solution Approach 2:
The patent changes the fundamental parameters of the reforming process by operating at room temperature instead of high temperature, and by using controlled mechanical rolling pressure instead of sustained hydraulic pressure. These parameter changes enable rapid reforming without the time-consuming heating and cooling cycles required by traditional methods.
2Manufacturing precision
If traditional hydraulic press is used to reform vessels, then the cavity can be reshaped, but the process becomes costly and time-consuming
Solution Approach 1:
The patent substitutes the complex hydraulic press system with a simpler mechanical roller system driven by a motor. This replacement eliminates the need for expensive hydraulic infrastructure and lengthy operation cycles, thereby improving productivity while maintaining the ability to reshape cavities with precision.
Solution Approach 2:
The patent achieves continuous useful action through the rotating rollers that continuously contact and reshape the vessel cavity as they rotate. This continuous rolling action is more efficient than the intermittent operation of hydraulic presses, maintaining constant productive work on the cavity throughout the reforming process.
3Loss of time
If rollers are used to reform vessel cavities, then reforming time is reduced, but the device complexity increases with multiple components
Solution Approach 1:
The patent applies universality by designing rollers that can perform multiple functions: they provide structural support, apply reforming pressure, and their surface profiles directly impart the desired cavity shape. This multi-functionality reduces the need for separate components, managing device complexity while achieving rapid reforming.
Solution Approach 2:
The patent segments the reforming function into multiple rollers with different surface profiles, allowing each roller to handle specific aspects of the cavity reshaping. This segmentation enables parallel action on different parts of the cavity, reducing total reforming time while organizing complexity into manageable, specialized components.
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 device enables rapid and effective reforming of vessel cavities, reducing production downtime by allowing for quick and precise reshaping of internal surfaces, with the ability to perform multiple operations like deburring and polishing.
Implementation Method 1
progressively reform vessel cavities by rotating and moving through the cavity, utilizing gear reduction and translation mechanisms for efficient deformation
Implementation Method 2
The rollers are rotated and moved through the cavity... The rollers may have a straight cylindrical surface or they may have a cambered or curved surface
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A device for reforming a vessel cavity is provided that includes a central shaft, a central gear coupled to the central shaft, and a plurality of roller gears coupled to the central gear, with each of the plurality of roller gears having a central portion. A proximal support member couples the plurality of roller gears and at least one of the central gear and the central shaft. A plurality of rollers is also provided, each of the plurality of rollers connected to the central portion of each of the plurality of roller gears. In one form, at least one idler member is disposed between the plurality of rollers. A distal support member couples the plurality of rollers and at least one of the central gear and a translation member. Also, a stationary member is secured to a distal portion of the vessel cavity.