Rotary Feedthrough Stator Composite Casting
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Solution Overview
Problem
The production of stators for rotary feedthroughs is inefficient and costly due to the need for extensive machining, particularly deep-hole drilling, which leads to dimensional inaccuracies, high tool wear, and increased manufacturing costs, especially for components with multiple channels.
Innovation Solution
A method involving the use of tubular inserts embedded in a carrier part during a casting process to form a composite cast part, where the inserts define the fluid channels, reducing the need for complex machining and allowing for the use of different materials with specific properties for inserts and carrier parts, enabling efficient production and adaptation to various configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional machining methods including deep-hole drilling are used to produce stators with multiple channels, then the stator can be manufactured with conventional processes, but the machining time is excessive and manufacturing costs increase significantly
Solution Approach 1:
The patent applies preliminary action by embedding tubular inserts that define the fluid channels into the carrier part before the final machining stage. These inserts are positioned and fixed in advance, so that the channel geometry is pre-established, eliminating the need for time-consuming deep-hole drilling operations during main production.
Solution Approach 2:
The tubular inserts serve as intermediary elements that mediate between the carrier part material and the final channel structure. Instead of directly machining channels into the solid carrier part, the inserts act as templates or formers that define the channel geometry, which is then integrated with the carrier part through machining and joining operations.
2Manufacturing precision
If deep-hole drilling is performed to create fluid channels in the stator, then channels can be formed in conventional manner, but dimensional inaccuracies occur and tool wear increases
Solution Approach 1:
The patent extracts the channel-forming function from the machining process itself and transfers it to the tubular inserts. Instead of using cutting tools to remove material and create channels, the inserts are embedded to define the channel geometry, thereby eliminating the harmful effects of deep-hole drilling such as tool wear and dimensional inaccuracies.
Solution Approach 2:
The tubular inserts serve as physical copies or templates of the desired channel geometry. The insert dimensions and shapes directly replicate the final channel requirements, ensuring dimensional accuracy without relying on complex machining operations that are prone to errors and tool degradation.
3Adaptability or versatility
If a single monolithic stator design is used, then the structure is simple, but flexibility for different configurations and material optimization is limited
Solution Approach 1:
The patent segments the stator into two distinct components: the carrier part and the tubular inserts. This segmentation allows each component to be optimized independently - the carrier part can be made from materials suitable for casting and joining, while the inserts can be made from materials specifically suited for fluid channel applications. Different insert configurations can be used to create various channel patterns without redesigning the entire stator.
Solution Approach 2:
The stator becomes a composite structure combining the carrier part material with the insert material. This composite approach enables the use of different materials with complementary properties in different regions of the stator, optimizing performance for both structural support and fluid channel functions, while also allowing flexibility in selecting materials based on specific application requirements.
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The invention relates to a method for manufacturing a rotary feedthrough (10) comprising a stator (50), comprising the steps of: providing at least one insert part (60, 62, 64, 66) that is at least partially tubular in design, arranging the at least one insert part (60, 62, 64, 66) in a casting tool (74), and forming a support part (86) by introducing a flowable material into the casting tool (74), wherein the at least one insert part (60, 62, 64, 66) is at least partially enclosed by the flowable material, and wherein the support part (86) and the at least one insert part (60, 62, 64, 66) are joined together to form a composite casting (52) on which the stator (50) is based. The invention further relates to a modularly manufactured component (50) for a rotary feedthrough (10), in particular a modularly manufactured stator, and advantageous uses of such components. (Fig. 6)