Transmission Engine Base Frame Spacer Welding
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Solution Overview
Problem
Current methods for producing geared motor units are costly due to the need for precise machining and additional manufacturing steps to achieve desired structural dimensions, which increases production costs and time.
Innovation Solution
A method involving a base frame and motor swing arm with spacers made from unmachined semi-finished products, where a compensating element like a washer is used to bridge the distance between parts, and a weld seam surrounds the compensating element to secure it, allowing for standardized components to be used without additional processing, thus reducing manufacturing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise machining and additional manufacturing steps are used to achieve desired structural dimensions, then manufacturing precision is improved, but production costs and device complexity increase
Solution Approach 1:
A compensating element (washer or spacer) is introduced as an intermediary component between the first and second parts. This compensating element bridges the distance between parts and is surrounded by a weld seam that does not directly touch it, allowing precise positioning and dimensional control without requiring complex machining operations on the main components.
Solution Approach 2:
The distance between parts is segmented into discrete standardized components (washers or spacers of specific thicknesses) rather than requiring continuous dimensional adjustment through machining. This segmentation allows selection of standard parts to achieve desired dimensions, eliminating the need for costly and time-consuming machining operations.
2Ease of manufacture
If standardized components are used without machining, then ease of manufacture is improved, but manufacturing precision may deteriorate
Solution Approach 1:
The compensating element serves as a precision intermediary that carries the dimensional tolerance burden. By surrounding the compensating element with a weld seam that does not directly contact it, the design allows standardized components to be used while maintaining precise overall dimensions through the controlled positioning of the compensating element.
Solution Approach 2:
The compensating element is designed as a simple, inexpensive standardized component (washer or spacer) that can be easily manufactured and replaced if needed. Its simplicity allows for high precision through standardization while keeping manufacturing costs low, as it does not require complex machining or expensive materials.
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
This approach reduces production costs by eliminating the need for machining and clamping, allowing for standardized parts to be used, and enables the production of geared motor units with adjustable dimensions without the need for complex manufacturing processes.
Implementation Method 1
the material connection is formed by at least one weld seam
Data Source
Figure 1
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Figure 3
AI summary
In a transmission-engine unit, a transmission (2) is mounted on a first spacer (18, 19, 24, 25, 51, 52, 74) while an engine is mounted on a second spacer (6, 7, 8, 22, 51, 52, 74). Both spacers are welded to a profiled tube (32), an engine rocker, or a base frame. A compensating element (42, 54) is inserted into at least one spacer (18, 19, 52, 74) before said spacer is welded to the profiled tube (32) in order to align the transmission (2) with the engine (1). The welded seam (57) connects the spacer (52, 74) to the profiled tube (32) and bridges the compensating element (42, 54).