Portable Tooling Apparatus with Variable Transmission Ratio
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Solution Overview
Problem
Existing portable and in-situ tooling apparatuses for railway rails and sleepers require significant operator experience and sensitivity to manage variations in friction, leading to potential jamming and tool breakage, as well as reduced tool lifespan due to sudden changes in resistance during material removal processes.
Innovation Solution
A portable apparatus with a motor and tool holder system featuring a transmission ratio adjuster that automatically compensates for changes in resistive torque by adjusting the cyclic movement speed of the tool holder in response to changes in motor speed and tool wear, thereby reducing the risk of jamming and maintaining consistent tool operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a power-driven tool is used for material removal, then productivity is improved, but the risk of jamming and tool breakage increases due to sudden changes in resistance
Solution Approach 1:
The patent applies a variable transmission ratio mechanism that dynamically adjusts the speed relationship between motor and tool holder based on operating conditions. When resistance increases (detected via motor speed reduction), the transmission ratio automatically increases to reduce tool holder speed and prevent jamming. This dynamic adaptation resolves the contradiction by allowing high productivity during normal operation while automatically reducing speed under high load to prevent failures.
Solution Approach 2:
The system uses motor speed as a feedback parameter to detect changes in resistive torque. The sensor monitors motor speed, and when a preset reduction is detected, this triggers the transmission ratio adjuster to increase the ratio, thereby reducing tool holder speed. This feedback loop enables the system to automatically respond to resistance changes and prevent jamming while maintaining high productivity during normal operation.
2Reliability
If operator experience and manual adjustment are required to manage friction variations, then tool reliability is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The system performs self-adjustment of the transmission ratio based on automatic detection of motor speed changes. Instead of requiring an experienced operator to manually adjust parameters based on sensory cues (vibrations, sound), the system autonomously monitors motor speed and automatically modifies the transmission ratio to maintain optimal operation. This eliminates the need for operator experience while maintaining tool reliability.
Solution Approach 2:
The patent replaces the manual mechanical adjustment system (requiring operator skill) with an automated sensor-based control system. The sensor detects motor speed changes and automatically triggers transmission ratio adjustment, substituting human sensory and manual adjustment mechanisms with electronic sensing and automatic mechanical adjustment.
3Productivity
If the motor speed is maintained at high levels, then productivity is improved, but the tool wear increases and component lifespan decreases
Solution Approach 1:
The variable transmission ratio mechanism dynamically adjusts operating conditions based on real-time motor speed. When the tool approaches wear (indicated by increased motor speed due to reduced resistance), the system automatically increases the transmission ratio to reduce tool holder speed. This dynamic adjustment allows the system to maintain high productivity during the tool's optimal life while automatically reducing speed to extend tool lifespan as wear progresses.
Data Source
AI summary
A portable apparatus (1) for the tooling of a workpiece (9) comprises a motor (3) with a cyclic movement output member (4), a tool holder (5) adapted to carry a tool (6) and a movement transmitter (7) engaging the motor output member (4) and the tool holder (5) to set the tool holder (5) in a cyclic movement, wherein the movement transmitter (7) comprises a transmission ratio adjuster (8) that, in response to a preset reduction of the cyclic movement speed (ω_m) of the output member (4) of the motor, increases the transmission ratio (ω_m/ω_ph) thereby reducing the cyclic movement speed (ω ph) of the tool holder (5) with respect to the cyclic movement speed (ω_m) of the output member (4) of the motor (3).