Phase-Adjustable Unbalance Exciter with Backlash Coupling
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Solution Overview
Problem
Existing unbalance exciters for soil compaction devices require numerous expensive components and complex hydraulic systems for phase adjustment, making them costly and prone to contamination.
Innovation Solution
An unbalance exciter with two parallel unbalance shafts, each with its own separately controllable drive, and a coupling device with a backlash mechanism to enable counter-rotation and phase adjustment without the need for complex hydraulic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex hydraulic system with multiple components is used for phase adjustment of unbalance shafts, then the unbalance exciter can achieve reversible operation and directional control, but the device complexity increases and the risk of contamination rises
Solution Approach 1:
The patent removes the hydraulic system entirely from the phase adjustment mechanism. Instead of using hydraulic pistons, gears, and hoses to adjust the phase between unbalance shafts, the invention uses a purely mechanical coupling device with inherent backlash that allows automatic phase adjustment through the natural rotation and slight relative movement of the shafts during operation.
Solution Approach 2:
The coupling device with backlash automatically adjusts the phase relationship between unbalance shafts through its own mechanical structure during normal operation. The backlash allows the shafts to have slight relative movement and phase adjustment without requiring external hydraulic actuation, making the system self-regulating and eliminating the need for complex control systems.
2Adaptability or versatility
If numerous expensive components including master cylinder, geared shaft, and adjustment cylinder are used for phase adjustment, then the unbalance exciter can switch directions, but the manufacturing cost increases
Solution Approach 1:
The patent extracts and removes all expensive hydraulic components (master cylinder, geared shaft, adjustment cylinder, seals, hydraulic hose) from the direction switching mechanism. The direction switching function is achieved through a simple mechanical coupling device with backlash that allows natural phase adjustment during shaft rotation.
Solution Approach 2:
The invention replaces expensive, complex hydraulic components with a simple, inexpensive mechanical coupling device that can be manufactured at low cost. The coupling device with backlash uses basic mechanical elements that are much cheaper than hydraulic systems while achieving the same directional control function.
3Ease of operation
If a hydraulic system is used for phase adjustment, then the unbalance exciter can be controlled, but the system becomes susceptible to contamination by chips
Solution Approach 1:
The patent replaces the hydraulic system with a purely mechanical coupling device. This substitution eliminates the sealed hydraulic circuits that are vulnerable to contamination from metal chips and other debris. The mechanical coupling with backlash is inherently more resistant to contamination as it uses open mechanical interfaces rather than sealed hydraulic passages.
Solution Approach 2:
The mechanical coupling device automatically maintains proper phase relationship through its inherent backlash design, without requiring controlled hydraulic fluid pressure that could be contaminated. The system self-regulates through mechanical clearance rather than fluid pressure control.
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 simplifies the construction of the unbalance exciter while maintaining its functionality, reducing costs and minimizing the risk of contamination, and allows for reversible operation and on-the-spot compaction.
Implementation Method 1
The coupling device comprises a backlash device for enabling a specific backlash in the rotational positions of the two unbalance shafts relative to one another
Implementation Method 2
each of which unbalance shafts bears eccentrically arranged weights (unbalance masses) in order to achieve the desired vibrations when the unbalance shafts rotate
Data Source
AI summary
An unbalance exciter is specified with at least two unbalance shafts arranged parallel to one another. Each of the unbalance shafts comprises its own, separately controllable drive for generating a drive torque. A coupling device is provided for coupling the two unbalance shafts so that they can counter-rotate. The coupling device comprises a backlash device for enabling a specific backlash in the rotational positions of the two unbalance shafts relative to one another. Backlash between the two unbalance shafts with a predetermined angle of rotation can be enabled by the backlash device, wherein the angle of rotation is selected from a range between 45° and 315°.