Rotating Spray Tray Lubrication for Uniform Forging Dies
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Solution Overview
Problem
Manual lubricant application on wheel hub forging dies results in inefficiencies, non-uniform lubrication, and production defects, hindering automation and productivity.
Innovation Solution
A die lubricant rotating spray tray device with symmetrical upper and lower parts, featuring rotating spray trays, nozzles, and transmission mechanisms driven by servo motors, ensuring uniform lubricant distribution on the maximum pitch circle surfaces of upper and lower dies through independently-communicated cavity pipelines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual lubrication is used on die working surfaces, then labor flexibility is maintained, but production efficiency is low and lubrication uniformity is poor
Solution Approach 1:
The patent employs rotating spray trays that can dynamically adjust their position and orientation to match the die working surfaces. The spray trays rotate to ensure complete coverage of the pitch circle surfaces, transforming a static manual process into a dynamic automated system that adapts to the geometry of the dies.
Solution Approach 2:
The patent replaces the manual mechanical spraying process with an automated rotating spray tray mechanism. The system uses rotational motion to automatically position nozzles and spray lubricant uniformly across the die surfaces, eliminating the need for manual operation while significantly improving productivity.
2Manufacturing precision
If fixed spray positioning is used, then device structure is simple, but lubricant cannot reach all areas uniformly
Solution Approach 1:
The rotating spray trays provide dynamic positioning capability, allowing the nozzles to move to different locations on the die surfaces. This rotational movement ensures that lubricant is distributed uniformly across all pitch circle surfaces, achieving complete coverage that fixed positioning cannot provide.
Solution Approach 2:
The spray system is divided into multiple independent spray trays, each responsible for specific areas of the die surfaces. The upper and lower spray trays can rotate independently to cover different sections, ensuring comprehensive and uniform lubrication distribution across the entire working surface.
3Manufacturing precision
If multiple spray points are added to improve coverage, then lubrication coverage is improved, but device complexity increases
Solution Approach 1:
The rotating spray trays serve multiple functions: they provide structural support for multiple nozzles, enable positional adjustment through rotation, and distribute lubricant to multiple areas sequentially. This multi-functionality reduces the need for separate positioning mechanisms and simplifies the overall device structure.
Solution Approach 2:
Instead of using multiple fixed nozzles positioned at different locations, the patent uses rotating spray trays that bring nozzles to different positions dynamically. This approach achieves comprehensive coverage with fewer nozzles, as the same nozzles serve multiple areas through rotational movement, reducing pipeline complexity.
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
Achieves uniform lubrication, reduces forging defects, increases automation, and enhances production efficiency by automatically controlling lubricant dosage and distribution.
Implementation Method 1
compressed air is input from the upper air pipe joints and the lower air pipe joints
Data Source
AI summary
Provided a die lubricant rotating spray tray device, wherein the nozzles, the connecting sleeve bodies, the nozzle connecting pipes, the air pipe joints and the lubricant pipe joints are sequentially connected to form independently-communicated cavity pipelines, compressed air is input from the air pipe joints, a lubricant is input from the lubricant pipe joints, the rotation driving mechanisms drive the spray tray rotators to rotate through the transmission mechanisms, and the spray tray rotators drive the nozzles to rotate, so that the same dosage of the lubricant is sprayed on the maximum pitch circle surfaces of upper and lower dies, the aim of uniformly spraying the forging lubricant on the working surfaces of the upper and lower dies is achieved.