Shape Adjusting Tool for Hollow Component Circularity
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Solution Overview
Problem
Existing tools for correcting the circularity of large-diameter thin-walled hollow components are often heavy, introduce distortions, and obstruct interior access for measurement or machining due to their mass and design.
Innovation Solution
A shape adjusting tool with a base structure, circumferentially distributed adjuster elements, a resilient adjustment ring, and a rotating mechanism that uses ramp arrangements to achieve radial displacement of adjuster elements, allowing for lightweight construction and internal access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional heavy tools are used for roundness correction, then correction capability is achieved, but the tool introduces further distortions and obstructs interior access
Solution Approach 1:
The tool is divided into multiple independent adjuster elements distributed around the circumference, each capable of individual radial adjustment. This segmentation allows localized correction of roundness errors without requiring a heavy monolithic structure, reducing overall tool mass and minimizing distortion of the workpiece.
Solution Approach 2:
The adjustment ring is made resilient in the circumferential direction, allowing it to flex and adapt to the workpiece geometry. This flexibility enables the tool to apply correction forces effectively while maintaining a lightweight structure, avoiding the need for heavy rigid construction that would cause obstruction and distortion.
2Force
If an array of bolts is used to drive the expander core, then expansion force is achieved, but the complexity of synchronized tightening increases
Solution Approach 1:
Multiple adjuster elements are merged into a single rotating adjustment ring structure. By rotating the ring, all adjuster elements are actuated simultaneously through integrated ramp arrangements, eliminating the need for separate bolt tightening operations and ensuring automatic synchronization of expansion forces.
Solution Approach 2:
The ramp arrangements act as intermediary mechanisms between the rotating adjustment ring and the adjuster elements. These ramps convert the rotational motion of the ring into synchronized radial displacement of all adjuster elements, providing a simple mechanical means to achieve uniform expansion without complex control systems.
3Strength
If a solid base structure is used, then structural strength is achieved, but the weight of the tool increases significantly
Solution Approach 1:
The base structure and adjustment ring are constructed from resilient sheet metal components rather than heavy solid materials. The sheet metal provides sufficient structural strength for force application while being lightweight, and the resilience of the adjustment ring in the circumferential direction provides the necessary flexibility for operation.
Solution Approach 2:
The adjustment ring is designed to be dynamically flexible in the circumferential direction while maintaining radial rigidity for force application. This dynamic characteristic allows the structure to adapt during operation without requiring excessive mass, achieving strength-to-weight optimization through controlled flexibility rather than brute-force rigidity.
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 tool effectively corrects the circularity of hollow components while minimizing distortion and obstruction, achieving high accuracy and tolerance with consistent radial displacement of adjuster elements, enabling precise shape adjustment and further processing.
Implementation Method 1
an adjustment ring which is mounted on the base structure for rotation about the axis, the adjustment ring being resilient in the circumferential direction
Implementation Method 2
a respective ramp arrangement being provided between each adjuster element and the adjustment ring whereby rotation of the adjustment ring causes radial displacement of each adjuster element
Data Source
Figure 1~2
Figure 3~5
AI summary
A hollow component is adjusted in shape, for example to correct circularity, by means of a shape adjusting tool. The tool comprises a base structure 2 on which adjuster elements 6 are guided. An adjustment ring 8 has a ramp surface 26 corresponding to each adjuster element 6 so that rotation of the adjustment ring 8 causes radial displacement of the adjuster elements 6. The adjuster elements 6 are displaced in unison, and engage the internal surface of the component to be adjusted so as to deform the component to the desired shape. The segments 20 are interconnected by rigid links 32 and a single flexible link 34, and are supported on baring rollers 36 mounted on the base structure 2.