Rotary Vane Actuator Side-Plate Reducing Dead Volume
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Solution Overview
Problem
The existing rotary vane actuators have inefficiencies due to the hollow plastic side-plates, which increase fluid usage and manufacturing costs, and are not feasible to produce as solid metal side-plates without distortion issues.
Innovation Solution
A two-part side-plate construction is introduced, where a strong outer part provides the external surface and a distinct inner part fills the internal volume, made from different materials to optimize strength and cost, reducing the need for a solid side-plate and minimizing dead volume in the cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a hollow plastic side-plate is used in the vane assembly, then manufacturing cost is reduced and ease of manufacture is improved, but fluid usage increases and manufacturing precision deteriorates due to distortion
Solution Approach 1:
The patent applies nesting by placing a metal insert (inner part) inside the hollow plastic side-plate (outer part). The metal insert is positioned within the internal volume of the plastic structure, creating a nested configuration where the stronger material reinforces the weaker material without requiring complete solidification of the entire side-plate.
Solution Approach 2:
The patent uses composite construction by combining plastic and metal materials in a single side-plate structure. The outer part is made of plastic for cost-effective manufacturing, while the inner part is made of metal for structural strength and precision, creating a composite component that leverages the advantages of both materials.
2Strength
If a solid metal side-plate is used to increase strength, then mechanical strength is improved, but manufacturing cost increases and manufacturing precision deteriorates due to distortion
Solution Approach 1:
The patent applies local quality by providing structural reinforcement only in specific areas where strength is needed. The metal insert is positioned strategically within the plastic side-plate to reinforce critical regions, rather than making the entire side-plate solid metal, thus optimizing strength where required while controlling cost.
Solution Approach 2:
The patent uses composite construction by combining plastic and metal materials in a single side-plate structure. The outer part is made of plastic for cost-effective manufacturing, while the inner part is made of metal for structural strength, creating a composite component that leverages the advantages of both materials.
3Ease of manufacture
If a hollow plastic side-plate is used to reduce cost, then manufacturing cost is reduced, but manufacturing precision deteriorates due to distortion
Solution Approach 1:
The patent applies nesting by placing a metal insert (inner part) inside the hollow plastic side-plate (outer part). The metal insert is positioned within the internal volume of the plastic structure, creating a nested configuration where the stronger material reinforces the weaker material without requiring complete solidification of the entire side-plate.
Solution Approach 2:
The patent uses composite construction by combining plastic and metal materials in a single side-plate structure. The outer part is made of plastic for cost-effective manufacturing, while the inner part is made of metal for structural strength and precision, creating a composite component that leverages the advantages of both materials.
4Quantity of substance
If the internal volume of the side-plate is filled to reduce dead volume, then fluid usage is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies nesting by placing a metal insert (inner part) inside the hollow plastic side-plate (outer part). The metal insert is positioned within the internal volume of the plastic structure, creating a nested configuration where the stronger material reinforces the weaker material without requiring complete solidification of the entire side-plate.
Solution Approach 2:
The patent applies segmentation by dividing the side-plate into two distinct parts: an outer plastic part and an inner metal insert. This segmentation allows each part to be manufactured separately using optimal processes for each material, then assembled together, reducing overall manufacturing complexity compared to creating a solid structure in one piece.
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 design reduces fluid usage and manufacturing costs while maintaining mechanical strength, improving the efficiency and cost-effectiveness of rotary vane actuators by minimizing dead volume and using lighter materials for the inner part.
Implementation Method 1
A pressure difference is therefore generated across the vane assembly between a higher pressure in the first chamber and a lower pressure in the second chamber. This pressure difference generates a torque on the vane assembly, resulting in rotational movement of the vane assembly in a direction away from the first chamber towards the second chamber.
Implementation Method 2
it is important that the vane assembly provides a seal between the first and second chambers so that the energy from the input flow of pressurised fluid is efficiently converted into rotational work, rather than being wasted by leaking between the first and second chambers around the vane assembly
Data Source
AI summary
A vane assembly for use in a rotary vane actuator, the vane assembly comprising: a rotatable vane having a first side and a second side; a vane axle connected to the rotatable vane for converting pressure exerted on the rotatable vane into rotational motion; a vane seal on the first side of the rotatable vane, the vane seal being for sealing the rotatable vane; and a side-plate on the first side of the rotatable vane, the side-plate clamping the vane seal in position; wherein the side-plate comprises: an outer part providing an outer surface of the side-plate, the outer part defining an internal volume; and an inner part filling or substantially filling the internal volume defined by the outer part, the inner part being distinct from the outer part.