Welded Retaining Elements for Diaphragm Actuator Output Rod
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Solution Overview
Problem
The existing production methods for fluid-operated diaphragm actuators are not cost-effective due to complex and costly fastening mechanisms for the drive diaphragm and output rod, which also lack efficient sealing and durable bonding.
Innovation Solution
The use of welded connections between the retaining elements and the output rod, allowing for a secure and durable clamping of the drive diaphragm, eliminating the need for additional sealing means and enabling efficient automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fastening mechanisms (screw connections, mounting bolts) are used to attach retaining elements to the output rod, then the assembly allows for disassembly and adjustment, but the production process becomes complex and costly with additional sealing requirements
Solution Approach 1:
The patent merges the fastening function and sealing function into a single welded connection between the retaining elements and the output rod. The welding process simultaneously attaches the retaining elements and creates the seal, eliminating the need for separate sealing components and reducing assembly complexity while lowering production costs
Solution Approach 2:
The patent replaces the mechanical fastening system (screws, bolts, nuts) with a welded connection. This substitution eliminates complex mechanical assembly steps, reduces the number of components, and simplifies the production process while maintaining secure attachment of the retaining elements to the output rod
2Reliability
If traditional fastening mechanisms with separate sealing means are used, then sealing can be provided, but the bonding durability and force transmission reliability are compromised
Solution Approach 1:
The patent combines the attachment function and sealing function into a single welded connection. The weld creates both the mechanical bond between the retaining elements and output rod, and the fluid seal, thereby improving bonding durability through a unified, integrated connection that eliminates potential failure points from separate components
3Productivity
If complex fastening mechanisms are used to secure the drive diaphragm, then sealing and durability are improved, but the automated production efficiency is reduced
Solution Approach 1:
The patent replaces complex mechanical fastening systems with welding, which is highly amenable to automated production. Welding processes can be easily automated with robots and fixtures, enabling high-speed assembly while maintaining consistent sealing quality and bonding durability, thereby improving automated production efficiency without compromising reliability
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 solution provides a cost-effective and efficient method for producing fluid-operated diaphragm actuators with a durable and secure bond, ensuring reliable force transmission and sealing, while simplifying the assembly process.
Implementation Method 1
the two retaining elements, independently of one another, by means of a welded connection in each case to the output rod
Implementation Method 2
an elastically deformable drive diaphragm having a central through hole
Data Source
AI summary
An operating unit for a fluid-operated diaphragm actuator, the unit consisting of a drive diaphragm, two retaining elements flanking the drive diaphragm on opposite sides and an output rod extending through these components. The drive diaphragm is mounted on the output rod by being clamped between the two retaining elements with a predetermined clamping force, wherein each of the two retaining elements is fixed on the output rod by means of a welded connection. A method that is particularly suitable for producing such an operating unit and to a fluid-operated diaphragm actuator equipped with such an operating unit.