Spider Lobe Twist Control System with Iterative Feedback
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Solution Overview
Problem
Traditional press machines for twisting spider lobes in axial fan assemblies face issues such as expensive and wear-prone cylindrical bearings, high scrap rates due to trial-and-error setup, and costly manual correction processes, leading to inefficiencies and increased production costs.
Innovation Solution
A manufacturing system with a control system that iteratively adjusts lobe clamps to achieve precise twist angles, using sensors and actuators to minimize scrap and rework, and a spider lobe clamp apparatus with a jaw lock mechanism for secure clamping to reduce twist angle variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional press machines with cylindrical bearings are used to twist spider lobes, then the twisting function is achieved, but the bearings wear rapidly and require frequent replacement, increasing operating costs
Solution Approach 1:
The patent removes the cylindrical bearings from the forming plates entirely, replacing them with a direct pivot connection between the clamping pads and forming plates. This extraction of the problematic bearing component eliminates the wear issue while maintaining the necessary pivoting function for lobe twisting.
2Duration of action of stationary object
If clearance is left between the upper forming plate and spider to protect bearings, then bearing lifespan is extended, but the spider lobes slide circumferentially between clamping pads causing twist angle variation
Solution Approach 1:
By removing the bearings entirely and using direct pivot connections, the invention eliminates the need for clearance between forming plates and spiders. The clamping pads can now apply full clamping force directly to the spiders without bearing interference, preventing lobe sliding while maintaining precision.
3Ease of operation
If trial-and-error setup method is used to adjust linkage for desired twist angles, then the press machine can be configured, but a large amount of scrap material is generated
Solution Approach 1:
The patent implements pre-calculated linkage settings based on spider dimensions and desired twist angles. Instead of trial-and-error adjustment, the linkage is pre-configured with precise geometric relationships that directly produce the target twist angle, eliminating setup scrap.
Solution Approach 2:
The system incorporates measurement and feedback mechanisms that monitor the actual twist angles produced and automatically adjust linkage settings. This closed-loop control ensures precise twist angles are achieved without requiring multiple trial spiders to be scrapped.
4Manufacturing precision
If manual correction processes are used to adjust twist angles after production, then individual spiders can be corrected, but the process is costly and time-consuming
Solution Approach 1:
The patent implements self-correcting mechanisms where the press machine automatically monitors and adjusts its own linkage settings based on measured twist angles. The system performs its own quality control and correction without requiring manual intervention, maintaining precision while preserving productivity.
Data Source
AI summary
In one aspect, a manufacturing system is provided having lobe clamps configured to secure lobes of a spider, drive assemblies configured to pivot the lobe clamps, sensors for detecting the position of the lobe clamps, and a control system operably coupled to the drive assemblies and configured to cause the drive assemblies to pivot the lobe clamps and impart a twist to lobes of the spider. In another aspect, a method is provided that includes twisting lobes of a spider in a first direction toward initial target positions using a machine, permitting the lobes to twist in a second direction toward free state positions, and twisting one or more of the lobes using the machine in response to the one or more lobes having free state positions different than final target positions of the lobes.