Shaft Mounting Device with Vibration Generator for Precision Alignment
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Solution Overview
Problem
Existing methods for mounting functional elements with cut-outs onto a shaft often result in misalignment, fretting, and chip formation due to incorrect positioning, especially when multiple elements are aligned simultaneously, leading to positional defects and increased risk of catching or tilting during the mounting process.
Innovation Solution
A device equipped with a vibration generator in the tailstock tip that generates constant, minimal vibrations to prevent adhesion and reduce contact forces between the functional elements and the shaft, allowing for precise alignment and improved manufacturing quality, featuring a movable guide slide and holders for each functional element, with the option to adjust vibration frequency and amplitude for enhanced cooling and reduced cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple functional elements are aligned simultaneously on a shaft, then productivity is improved, but manufacturing precision deteriorates due to misalignment and positional defects
Solution Approach 1:
The patent applies mechanical vibration through a vibration generator that vibrates the shaft during the mounting process. This vibration prevents adhesion between the functional elements and shaft, reduces contact forces, and eliminates catching or tilting of functional elements, thereby maintaining high alignment precision even when multiple elements are mounted simultaneously
Solution Approach 2:
The patent changes the physical state of the mounting process by introducing vibrational motion as an additional parameter. The vibration frequency and amplitude are controlled to optimize the mounting process, allowing multiple functional elements to be aligned precisely while increasing productivity
2Ease of operation
If functional elements are heated and then mounted onto a shaft, then ease of operation is improved, but object-generated harmful factors worsen due to fretting and chip formation
Solution Approach 1:
The vibration generator creates controlled vibrations that reduce contact forces between functional elements and the shaft during mounting. This prevents fretting and chip formation that would otherwise occur when heated functional elements are pressed onto the shaft, eliminating harmful effects while maintaining ease of operation
Solution Approach 2:
The vibration applied during mounting provides periodic motion that prevents continuous contact and adhesion between surfaces. This periodic action reduces the cumulative effect of contact forces, preventing fretting and chip formation during the heating and mounting process
3Productivity
If the shaft is passed through multiple functional elements, then productivity is improved, but reliability deteriorates due to increased risk of catching and tilting
Solution Approach 1:
The vibration generator vibrates the shaft as it passes through multiple functional elements, preventing adhesion and reducing contact forces. This eliminates the catching or tilting of functional elements that would compromise reliability, while still allowing efficient passage through multiple elements to maintain high productivity
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 device ensures high-quality mounting by preventing misalignment and adhesion, reducing contact forces, and facilitating faster cooling, resulting in improved manufacturing precision and reduced cycle times, especially when multiple functional elements are mounted.
Implementation Method 1
a vibration generator 9, by means of which the shaft 2 and furthermore also the functional element 4 can be set in vibration
Implementation Method 2
the at least one functional element (4) to be joined is heated and then the camshaft tube or generally a shaft is introduced
Implementation Method 3
the first functional element passed through, for example the first cam passed through, is already cooled and thus the clearance available for passing through becomes increasingly smaller
Data Source
AI summary
A device for mounting at least one receiving element on a shaft may include at least one holder for holding a receiving element having a cut-out for receiving a shaft. A moveable guide slide may be configured to move the shaft in a first direction through the cut-out in the receiving element. A tailstock may be configured to move counter to the first direction. The tailstock may include a tailstock tip configured to couple to an end face of the shaft. A vibration generator may be arranged in the tailstock for vibrating the shaft.