Shielded Friction Wheel Extrusion for Low-Oxygen Profile Forming
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Solution Overview
Problem
Existing extrusion machines face challenges in maintaining safe and economical operation, producing high-quality profiles, preventing oxygen absorption during the forming process, and facilitating easy and safe friction wheel changes.
Innovation Solution
The extrusion machine incorporates a shielding unit to minimize oxygen ingress, a sensor system for real-time force monitoring, and improved mechanisms for friction wheel replacement, including a cantilever arm and guide arrangement to enhance accessibility and safety during changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If no shielding unit is provided, then the structure is simpler, but oxygen absorption into the heated extruded material occurs, reducing profile quality
Solution Approach 1:
The patent applies an inert atmosphere principle by introducing a shielding unit that emits gas free of gaseous oxygen (such as nitrogen or other inert gases) to create an oxygen-free environment around the heated extruded material. This prevents oxidation and oxygen absorption during the friction welding process, thereby maintaining high profile quality without requiring complex additional mechanisms beyond the gas supply system.
2Ease of operation
If friction wheel replacement requires dismantling the drive shaft, then the friction wheel can be replaced, but accessibility and ease of handling are insufficient
Solution Approach 1:
The patent applies segmentation by dividing the drive shaft into modular sections with friction wheels that can be independently removed. The drive shaft is designed with accessible interfaces that allow friction wheels to be detached without dismantling the entire drive shaft structure, significantly improving ease of replacement while maintaining structural integrity.
Solution Approach 2:
The patent enables extraction of friction wheels from the drive shaft assembly through designed access points and removable connections. This allows friction wheels to be taken out for replacement or maintenance without requiring disassembly of the main drive shaft structure, improving operational ease while keeping the overall system simple.
3Reliability
If no sensor system is provided, then the device is simpler, but overload detection is delayed until damage occurs
Solution Approach 1:
The patent implements feedback by incorporating sensor systems that continuously monitor operational parameters such as force, torque, or power during friction wheel operation. When abnormal conditions or overloads are detected, the sensors provide real-time feedback to the control system, enabling immediate response before damage occurs. This enhances reliability while adding only minimal sensor components rather than complex systems.
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 solution ensures higher profile quality by preventing oxygen absorption, allows for safer and more efficient operation by detecting overloads, and simplifies the friction wheel change process, reducing the risk of accidents and increasing user-friendliness.
Implementation Method 1
a shielding unit is provided, the shielding unit comprises at least one first nozzle and at least one second nozzle, the at least one first nozzle and the at least one second nozzle are each designed to emit a gas free of gaseous oxygen in order to minimize or prevent access of ambient air to the heated extruded material
Implementation Method 2
wherein the extruded material to be formed is heated to the required forming temperature by the friction wheel
Data Source
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AI summary
The invention relates to an extrusion machine (1) for the continuous production of profiles (2) from a formable extrusion material (3). The extrusion machine (1) comprises a base frame (5), a friction wheel (4) driven by a drive unit (45), a bearing unit (48) with a first bearing device (49) and a second bearing device (50), and a tool holding device (6) with a tool unit (12).Furthermore, a shielding unit (28) is provided with at least one first nozzle (32) and at least one second nozzle (33), wherein the at least one first nozzle (32) and the at least one second nozzle (33) are each designed to release a gas free of gaseous oxygen, the at least one first nozzle (32) is directed towards a circumferential section (29) of the friction wheel (4), which circumferential section (29) is provided for contact with the supplied extrusion material (3), and the at least one second nozzle (33) is arranged below the stripping area (30) of the tool unit (12).