Shaft Component Machining for Precise Fluid Channel Contours
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Solution Overview
Problem
The existing methods for producing individually manufactured manhole components are time-consuming, costly, and result in large tolerances and rough surfaces, making them expensive and inefficient, especially when producing angled channels or complex shapes, which can lead to obstacles in fluid outflow and require laborious reassembly or discarding of pre-assembled components.
Innovation Solution
A method involving data processing to generate data sets for controlling machines in material removal and build-up processes, using 3D printing and milling, to create manhole components with precise specifications, including sequences of milling paths and tool selections, allowing for efficient and cost-effective production of manhole components with fluid-tight connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individually manufactured shafts are produced using traditional manual or semi-automated assembly methods, then custom specifications can be achieved, but production time and costs increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-defining standardized shaft components with common configurations (straight passages, inlets at predefined angles in a 15° grid). These pre-configured components are ready for assembly before the actual manufacturing process begins, eliminating the need for custom fabrication of each shaft. The system allows planners to select from predefined configurations and automatically generates assembly instructions, enabling rapid production of custom shafts through pre-planned standardized components.
2Adaptability or versatility
If individually manufactured shafts are produced using traditional methods, then custom specifications can be achieved, but production costs increase due to significant labor requirements
Solution Approach 1:
The patent implements self-service by providing the system with automatic data processing and assembly instruction generation capabilities. The software automatically reads civil engineering plans, processes the data, selects appropriate standardized components, and generates assembly instructions without requiring manual intervention. This automation eliminates the need for expensive manual labor in the planning and assembly phases, making custom shaft production cost-effective.
3Adaptability or versatility
If pre-fabricated shaft components are assembled manually or semi-automatically, then individual customization is possible, but precise pre-planning is required which increases complexity
Solution Approach 1:
The patent replaces the mechanical/manual system of pre-planning with an automated computer-based system. The software automatically processes civil engineering plans, interprets requirements, selects appropriate standardized shaft components, and generates assembly instructions. This substitution of manual mechanical planning with automated digital processing dramatically reduces pre-planning complexity while maintaining full customization capability.
4Ease of manufacture
If traditional manufacturing methods are used for shaft components, then production can proceed with available tools, but large tolerances and rough surfaces result which impede fluid flow
Solution Approach 1:
The patent applies parameter changes by specifying tight tolerance ranges and surface quality requirements for the standardized shaft components. The system defines precise dimensional tolerances and surface finish parameters that components must meet during manufacturing. By controlling these parameters through automated selection and specification, the system ensures smooth surfaces and accurate tolerances that prevent fluid flow obstructions while maintaining manufacturing feasibility.
5Ease of manufacture
If segment-welded pipe bends are used to create angled channels, then straight pipes and sheets can be utilized, but deviations from ideal curves create obstructions and require additional work
Solution Approach 1:
The patent applies preliminary action by pre-defining optimal channel configurations and bend angles in the standardized shaft component library. Instead of creating bends during assembly from straight pipes, the system pre-calculates and pre-specifies the ideal channel geometries and bend parameters. This allows manufacturers to produce shafts with precise curved channels using appropriate forming tools, eliminating the need for segment-welded approximations and ensuring smooth fluid flow paths.
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
Enables the production of manhole components that are precisely manufactured according to specifications, reducing manufacturing time and costs, ensuring fluid-tight connections, and allowing for easy assembly and adjustment during construction, while minimizing material waste and rework.
Implementation Method 1
a machine for material removal and/or material build-up from or on a body (9), wherein the functional contour (2) of the shaft component or shaft section or shaft is formed at least section by section from the body (9) by material removal and/or material build-up
Implementation Method 2
with the aid of the machine (15) for material removal by milling and/or material build-up by a 3D printing process
Data Source
Figure 1(A)~1(D)
Figure 2
AI summary
The invention relates to a method for producing a shaft component (1), a shaft section, or a shaft, having a functional contour (2) with a channel (3), with which fluid can be conducted, with at least one feed device (5) in order to feed fluid to the shaft component (1), the shaft section, or the shaft, and with at least one discharge device (6) in order to discharge fluid from the shaft component (1), the shaft section, or the shaft, wherein the shaft component (1) or the shaft section has a connection section (7) for fluidically connecting the shaft component (1) or the shaft section to a component. The method has the steps of: (A) reading or entering data into a data processing machine (12); (B) generating a first data set (13) from the data read into the data processing machine (12); (C) generating a second data set (14) which is suitable for controlling a machine (15) for removing material and/or assembling material from and/or on a body (9); and (D) producing the shaft component (1), the shaft section, or the shaft from the body (9) using a machine (15).