Rotating Roller Jig for Uniform Heating of Ring Workpieces
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Solution Overview
Problem
Existing heat treatment apparatuses for ring-shaped workpieces face challenges in efficiently heating large workpieces due to complex positioning structures, limited versatility, and potential deformation from uneven heating and stress application, particularly when using turntables or rollers.
Innovation Solution
A jig system with a central structure unit and rotating rollers that supports the workpiece, allowing for rotation and suspension during heating, featuring a conveyor mechanism for easy transfer between loading and heating sections, and a cooling section for efficient cooling, enabling precise positioning and uniform heating without clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a turntable is used to support and rotate the ring-shaped workpiece, then the workpiece can be heated uniformly while rotating, but the positioning structure becomes complex and the workpiece needs to have a specific shape to fit the turntable
Solution Approach 1:
The jig is designed with a universal interface that can accommodate different ring-shaped workpieces without requiring custom turntables for each workpiece. The workpiece support unit with multiple rotating rollers can handle various sizes and shapes of ring-shaped workpieces, making the heating apparatus versatile and adaptable to different workpiece types.
Solution Approach 2:
The workpiece support unit uses multiple rotating rollers that can independently rotate to support and rotate the workpiece dynamically. This dynamic support system replaces the rigid turntable structure, allowing the workpiece to be rotated smoothly without requiring a fixed shape match, thereby simplifying the positioning structure while maintaining heating uniformity.
2Ease of operation
If separate support tools are used for carrying in and heating the workpiece, then the workpiece can be conveyed and heated, but the configuration becomes complex and positioning accuracy is difficult to maintain
Solution Approach 1:
The jig combines the functions of conveyance support and heating support into a single integrated structure. The workpiece support unit serves both to support the workpiece during conveyance and during heating operations, eliminating the need for separate support tools. This merging of functions simplifies the overall configuration while maintaining ease of operation for both conveyance and heating processes.
3Measurement precision
If positioning rollers press the inner or outer surface of the workpiece, then the workpiece can be positioned accurately, but stress is applied to the heated and softened workpiece causing deformation
Solution Approach 1:
The workpiece support unit uses rotating rollers that support the workpiece from below through gravitational force, counteracting the need for pressing forces. The rollers rotate to maintain contact with the workpiece surface without applying compressive stress, thereby positioning the workpiece accurately while preventing deformation during heating when the material is softened.
4Weight of moving object
If the workpiece is large, then the gravity center adjustment becomes difficult for stable conveyance, but heating is still required
Solution Approach 1:
The jig uses a dynamic support system with multiple rotating rollers that can adapt to the weight distribution of large workpieces. The rollers rotate to maintain stable contact points, automatically adjusting to the workpiece's gravity center without requiring manual adjustment. This dynamic adaptation ensures stable conveyance and heating of large workpieces while simplifying operation.
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
Facilitates easier and more versatile heat treatment of large ring-shaped workpieces with reduced deformation and stress, allowing for accurate and uniform heating across the entire circumference, and simplifies the configuration and operation of the heat treatment process.
Implementation Method 1
a radially outer surface or a radially inner surface of the annular member is pressed by three or more positioning rollers to position the annular member. The annular member is induction-heated by heating coils while being rotated.
Data Source
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AI summary
A jig of a heating apparatus is provided. The jig supports a ring-shaped workpiece when conveying and heating the workpiece. The jig includes a central structure unit, a rotary drive mechanism accommodated in the central structure unit, and a workpiece support connected to the central structure unit and configured such that the workpiece is placed on the workpiece support to surround the central structure unit. The workpiece support includes a plurality of rotating rollers arranged in a circumferential direction around the central structure unit. The central structure unit includes a conveyor connecting portion to suspend the workpiece support together with the workpiece placed on the workpiece support, and a driver connecting portion from which a driving force is input to the rotary drive mechanism. The rotary drive mechanism rotates the rotating rollers by the driving force to rotate the workpiece along a ring shape of the workpiece.