Radial Vane Fold-Over Manufacturing Eliminates Cut Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional radial vane manufacturing methods result in significant cut loss and increased manufacturing costs due to the need for separate thread bundle removal, and the annular core part is prone to breakage or loose fitting on the shaft, leading to defective products and precision issues.
Innovation Solution
A fold-over manufacturing method where a continuous thread bundle is radially opened and superposed with a space in the center, allowing for annular welding without separation, forming a thick, elastic annular fold-over part that serves as a boss and grip, reducing cut loss and enhancing mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thread bundle separation method is used to manufacture radial vane, then manufacturing process is simple, but cut loss increases and manufacturing cost increases
Solution Approach 1:
The patent merges the thread bundle with the annular core part by welding the both ends of the thread bundle to the core part, eliminating the need for separate removal processes. This combining approach reduces material loss while maintaining manufacturing simplicity.
Solution Approach 2:
The patent performs preliminary welding of the thread bundle ends to the annular core part before final assembly. This preliminary action prevents subsequent removal operations, thereby eliminating cut loss and reducing manufacturing costs.
2Ease of manufacture
If conventional annular core part structure is used, then manufacturing is easier, but the core part is prone to breakage or loose fitting on the shaft
Solution Approach 1:
The patent introduces an annular groove with a curved cross-section into the annular core part. This curved structure provides elastic deformation capability, allowing the core part to securely fit the shaft while resisting breakage through flexible stress distribution.
Solution Approach 2:
The patent changes the structural parameters of the annular core part by adding the annular groove, which modifies the mechanical properties. The groove creates elastic deformation characteristics that improve both fit security and breakage resistance without complicating the manufacturing process.
3Ease of manufacture
If through hole diameter is not precisely controlled, then manufacturing is simpler, but fitting precision on shaft deteriorates
Solution Approach 1:
The annular groove with curved cross-section compensates for diameter variations through elastic deformation. This curved structure allows the core part to adapt to slight diameter differences, maintaining precise fitting without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The patent uses the annular groove to dynamically adjust the effective diameter through elastic deformation. This parameter change capability allows the core part to achieve precise fitting on the shaft even when the base through hole diameter has normal manufacturing tolerances.
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 method eliminates cut loss, reduces manufacturing costs, allows for precise adjustment of the through hole diameter, and ensures a secure, non-rotating fit of the radial vane on the shaft, minimizing defective articles and improving mechanical strength.
Implementation Method 1
The welding head 40 is a welding horn which carries out welding on the basis of supersonic vibration, and is oscillated and driven by a vibrator (not shown)
Implementation Method 2
the center part of the radially opened thread materials 21 is promoted to be welded by heat transmission from the periphery of the center part
Data Source
Figure 1(a)~1(c)
Figure 2~3
Figure 4
AI summary
Provided is a radial vane with which manufacturing is possible with superior economy, without incurring a cut loss associated with vane separation in a weld part of a thread bundle. With a longitudinal intermediate part of a contiguous bundle of threads being a fold-over part, both end parts of the fold-over part of the thread bundle are opened into radial shapes and superpositioned, leaving a space in the center part of the fold-over part, a ring-shaped fold-over part (12) is formed within the circumference of the space in the center part thereof. The outer part of the ring-shaped fold-over part (12) is welded in a ring shape, forming a ring-shaped core part (13). A through hole (11) is formed in the inner side of the fold-over part (12), and radial vane parts (14) are formed in which a plurality of thread materials (21) extend outward from the core part (13) toward the outer circumference side from all regions of the circumference direction. The ring-shaped fold-over part (12) is either an un-welded part or an incompletely welded part which protrudes in a dome shape in both surfaces and protrudes in an arch shape into the center, and is also efficacious as a boss part for gap adjustment when a plurality of radial vanes (10) are fixed in an axle, forming a brush head, as well as functioning simultaneously as a slide part which makes fixing easy, and as a grip part which anchors the fixed vanes.