Rotating Component Balancing with Segmented Pins
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Solution Overview
Problem
Existing methods for balancing rotating components in electrical machines, such as using cylindrical pins or balancing cement, often result in insufficient balancing quality, particularly in high-precision applications like electric motors in automobiles, leading to potential machine destruction due to unbalanced rotational stress.
Innovation Solution
The method involves fixing pins of different cross-sectional areas in corresponding openings, using a combination of large and small cross-sectional area pins, with a focus on cylindrical pins and varying materials, and employing an adhesive connection for precise balancing, allowing for a multi-stage process that can be automated, reducing the need for trained personnel and ensuring consistent high quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cylindrical pins with fixed cross-sectional area are used for balancing, then the balancing process is simple and can be automated, but the balancing quality is insufficient
Solution Approach 1:
The balancing mass is segmented into multiple pins with different cross-sectional areas instead of using a single pin. This allows for finer adjustment of the balancing mass distribution, improving balancing quality while maintaining the automated pin-insertion process
Solution Approach 2:
Different regions of the balancing plane are assigned different pin cross-sectional areas. By selecting specific pin sizes for specific openings based on the imbalance characteristics, the method achieves high balancing precision while keeping the overall process automated and simple
2Manufacturing precision
If balancing compound is applied to achieve high balancing accuracy, then the balancing quality is high, but the process requires highly trained personnel and is complex
Solution Approach 1:
The method replaces the manual application process of balancing compound with an automated mechanical pin-insertion system. The pins are inserted into pre-drilled openings using automated equipment, eliminating the need for highly trained personnel while achieving comparable or superior balancing accuracy
Solution Approach 2:
Instead of varying the amount of balancing compound (which requires manual skill), the method varies the cross-sectional area of the pins as a discrete parameter. This transforms a continuous adjustment problem into a discrete selection problem, enabling automation while maintaining high balancing accuracy
3Manufacturing precision
If multiple pins with different cross-sectional areas are used, then the balancing quality is significantly improved, but the number of pin types and openings increases
Solution Approach 1:
Multiple pin types with different cross-sectional areas are designed to fit into the same standardized opening structure. The openings are universally designed to accommodate different pin sizes, reducing the need for different opening locations and simplifying the overall system architecture
Solution Approach 2:
The openings for different pin sizes are pre-planned and pre-drilled during component manufacturing. This preliminary action ensures that the component structure is ready to receive multiple pin types without requiring additional complex setup or modification during the balancing process
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 approach achieves a significantly higher balancing quality, extending the service life of electrical machines while reducing production costs, by precisely adjusting the mass distribution and stabilizing the component, even in compact designs, and allows for automation in series production.
Implementation Method 1
The pins can be fixed by a force-fit connection through a press-fit process, by bonding, or by screwing. A screw connection is particularly suitable for cylindrical pins and can be combined with an adhesive bond. Fixing the pins in the corresponding opening using an adhesive bond has proven to be the most effective method for this process.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The method involves arranging cylinder or angular-shaped pins into prefabricated apertures (5, 7, 9) in a component (1). The component is balanced into the respective apertures by using the cylinder or angular-shaped pins with different sizes, where the cylinder or angular-shaped pins are manufactured from aluminum, steel, zinc, tungsten, lead, resin or plastic. The cylinder or angular-shaped pins are arranged together to form cross section areas with different sizes. The cylinder or angular-shaped pins are inserted in the apertures after determination of imbalance of the component. Independent claims are also included for the following: (1) a component (2) an electrical rotating machine (3) a device for heaving a component.