Rotary Worktable Insulation Using a Coated Metal Adapter
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Solution Overview
Problem
As the size of the worktable increases, the size of the insulating ring also increases, making it difficult and costly to produce insulating rings with high rigidity and insulating properties, such as Bakelite, which are needed to reliably electrically insulate the worktable from the motor in arc welding applications.
Innovation Solution
A workpiece support device that uses a metal adapter with an insulating coating film between the worktable and the reducer, eliminating the need for a large insulating ring by ensuring electrical insulation through the adapter's coating, thereby reducing production costs and maintaining high insulating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large insulating ring made of resin (e.g., Bakelite) is used to electrically insulate the worktable from the motor, then reliable electrical insulation is achieved, but production cost and manufacturing difficulty increase significantly
Solution Approach 1:
The patent replaces the expensive, large resin insulating ring with a metal adapter that is coated with an insulating layer. This approach uses a cheaper metal base material (such as aluminum or steel) combined with a relatively thin insulating coating, significantly reducing material costs and manufacturing complexity while maintaining adequate insulation performance for the application
Solution Approach 2:
The patent employs a composite structure consisting of a metal adapter body combined with an insulating coating layer (such as paint, powder coating, or other insulating materials). This composite approach leverages the mechanical strength and ease of fabrication of metal while adding the electrical insulation properties of the coating, achieving a cost-effective solution that meets both structural and electrical requirements
2Productivity
If the worktable size is increased to accommodate larger workpieces, then productivity and versatility improve, but the required insulating ring size and cost increase
Solution Approach 1:
By using a metal adapter with insulating coating instead of a large resin insulating ring, the patent enables scaling to larger worktable sizes without proportionally increasing insulation component costs. The metal adapter can be easily fabricated in various sizes, and the insulating coating provides sufficient protection at minimal material cost, allowing the system to accommodate larger workpieces economically
3Reliability
If a thick insulating ring is used to prevent welding current from flowing through the insulating ring thickness, then electrical insulation reliability improves, but device complexity and space requirements increase
Solution Approach 1:
The patent replaces the thick, rigid resin insulating ring with a thin insulating coating applied to the metal adapter surface. This thin film approach provides adequate electrical insulation without requiring large thickness, reducing the overall size and complexity of the insulation component while maintaining effective prevention of current leakage
Solution Approach 2:
The insulating coating can be applied as a relatively thin layer through standard coating processes, eliminating the need for thick material sections. This reduces both material usage and manufacturing complexity while providing sufficient insulation performance for the welding application
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 solution effectively prevents electrical conduction between the worktable and the reducer, achieving reliable insulation and reducing production costs by using a metal adapter with an insulating coating film instead of a large insulating ring, thus addressing the challenge of scaling up the workpiece support device.
Implementation Method 1
the worktable and the adapter are electrically insulated by an insulating coating film formed by a surface treatment on a surface of the worktable or the adapter
Data Source
AI summary
A workpiece support device including a base, an electrically conductive worktable rotatably supported with respect to the base, a motor, a reducer that transmits rotation of the motor to the worktable and reduces a speed of the rotation, and a metal adapter interposed between the worktable and the reducer to separate the worktable and the reducer from each other. The worktable and the adapter are electrically insulated by an insulating coating film formed by a surface treatment on a surface of the worktable or the adapter.