Rotary Work Device Servomotor Speed Control

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Solution Overview

Problem

Existing rotary work devices for spot welding in automobile production lines require extensive modifications and increased costs due to differing rotator sizes and complex gear configurations, limiting versatility and efficiency in electrode detachment and cutting operations.

Innovation Solution

A rotary work device with two rotators of the same outside diameter, rotated by a single intermediate gear, and controlled by a servomotor to achieve different rotational speeds for detachment and cutting operations, allowing for interchangeable holder and cutter configurations and reduced gear complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If two rotators have different outside diameters to achieve different rotational speeds for detachment and cutting operations, then the rotational speed requirement is satisfied, but the device complexity and cost increase due to multiple gears and asymmetric configuration

Engineering Contradiction:

Improverotational speed of rotatorsVSAvoidgear configuration complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent changes the parameter of rotational speed control from mechanical gear ratio differences to electronic speed control. The servomotor controller independently controls the rotational speed of each rotator, allowing different speeds without different gear configurations. This resolves the contradiction by decoupling speed differentiation from mechanical complexity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent makes both rotators have the same outside diameter and interchangeable holder/cutter configurations. Each rotator can accommodate either a holder or a cutter, and both can be controlled independently to different speeds. This universal design reduces device complexity while maintaining the ability to achieve different rotational speeds for different operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Speed

If two rotators have different outside diameters to achieve different rotational speeds, then the operational requirements are met, but the device size increases and symmetric placement becomes difficult

Engineering Contradiction:

Improverotational speed differentiationVSAvoiddevice size

Core Design Contradiction:

SpeedVSVolume of moving object

Solution Approach 1:

The patent equalizes the outside diameters of both rotators, making them compact and identical in size. The rotational speed differentiation is achieved through electronic control of the servomotor rather than through size differences. This resolves the contradiction by separating speed control from physical dimensions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates symmetry in the device by making both rotators identical in size and configuration. This symmetric design allows for easy symmetric placement in production lines and reduces overall device size, while the asymmetric rotational speeds are achieved through electronic control rather than mechanical asymmetry.

Inventive Principle:

Principle #4Asymmetry

3Adaptability or versatility

If extensive modifications are made to internal structure to exchange positions of holder and cutter, then the operational flexibility is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improveinterchangeability of holder and cutterVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent designs both rotators with identical outside diameters and interchangeable holder/cutter mounting configurations. This allows the holder and cutter to be exchanged between rotators without modifying the internal structure. The universal design reduces manufacturing cost while maintaining high operational flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates a dynamically reconfigurable system where the holder and cutter can be easily exchanged between rotators. The identical rotator designs and standardized mounting interfaces enable quick reconfiguration without extensive modifications, reducing both manufacturing cost and setup time.

Inventive Principle:

Principle #15Dynamics

4Speed

If multiple gears are used to control rotational speeds of different sized rotators, then the speed control is achieved, but the reliability decreases due to increased risk of servomotor failure

Engineering Contradiction:

Improverotational speed controlVSAvoidservomotor failure risk

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent replaces the mechanical gear transmission system with an electronic speed control system. The servomotor controller directly controls the rotational speed of each rotator without intermediate gears. This eliminates gear-related failure points and reduces the overall risk of servomotor failure, while maintaining precise speed control capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9505080B2Rotary work device

Publication Date: 2016.11.29 KYOKUTOH

AI summary

A rotary work device includes: a first output gear into which a holder is fitted; a second output gear into which a cutter is fitted; a second intermediate gear meshing with both the output gears; and a servomotor rotating the second intermediate gear. A control panel includes a memory storing a first rotational speed and a second rotational speed that is higher than the first rotational speed. When an electrode detachment operation is performed, both the output gears are rotated at the first rotational speed, and when an electrode cutting operation is performed, both the output gears are rotated at the second rotational speed.