Deburring Device for Wheel Back Cavity with Adjustable Brush System
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Solution Overview
Problem
Current deburring methods for aluminum-alloy wheels are inadequate, particularly for complex shapes, and traditional equipment is inflexible, requiring frequent changes in brush systems when switching between different wheel sizes, which significantly affects production efficiency.
Innovation Solution
A deburring device with an automatically adjustable brush system that allows for brushing forces of different directions to be applied to the back cavity of a wheel, utilizing a complex mechanism involving motors, belt pulleys, synchronizing belts, gear racks, and servo motors to accommodate wheels of various sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional deburring equipment is used with fixed brush systems, then the structure is simple and easy to operate, but the adaptability to different wheel sizes and shapes is poor, requiring frequent replacement of brush systems
Solution Approach 1:
The patent implements a dynamically adjustable brush system where the brush wheel diameter can be continuously changed during operation. The brush wheel comprises multiple adjustable brush layers that can be independently positioned along the radial direction, allowing the effective brushing radius to be adapted to different wheel sizes without replacing entire brush systems. This dynamic adjustment capability resolves the contradiction between adaptability and device complexity.
Solution Approach 2:
The deburring device is designed with a universal brush system that can handle multiple wheel types and sizes through automated adjustment. The control system receives wheel dimension information and automatically configures the brush parameters (diameter, pressure, rotation speed) to match different wheel specifications, making a single device capable of performing deburring operations on various wheel variants without requiring multiple dedicated brush systems.
2Adaptability or versatility
If traditional deburring equipment with single-direction brushing is used, then the device complexity is low, but the ability to remove burrs from complex shapes is insufficient
Solution Approach 1:
The brush system is segmented into multiple independent brushing units arranged in different spatial directions. Each brush layer can be independently controlled and positioned, allowing selective activation of specific brushing directions based on the wheel geometry and burr location. This segmentation enables comprehensive coverage of complex wheel surfaces while maintaining manageable system complexity through modular control.
Solution Approach 2:
The patent transitions from single-direction brushing to multi-dimensional brushing by arranging brush layers radially and axially. The brush wheels can rotate around the wheel circumference while also applying radial pressure, creating two-dimensional brushing coverage. Additionally, multiple brush layers at different angular positions provide three-dimensional deburring capability, effectively removing burrs from complex surfaces that single-direction brushes cannot access.
3Productivity
If frequent replacement of brush systems is performed for different wheel sizes, then the device can be optimized for each wheel type, but the production efficiency is seriously affected
Solution Approach 1:
The deburring device incorporates an automated control system that performs self-adjustment of brush parameters based on input wheel dimension data. The system automatically calculates and configures the optimal brush diameter, pressure, and rotation speed without requiring manual intervention or physical replacement of brush components. This self-service capability eliminates downtime associated with brush system changes and maintains continuous production flow.
Solution Approach 2:
The patent implements dynamic parameter adjustment of the brush system through electronic control. Instead of physically replacing brush systems, the control system modifies operational parameters (brush wheel rotation speed, radial pressure, effective radius) to match different wheel specifications. This parameter-based adaptation allows instantaneous reconfiguration between different wheel types, eliminating the time loss associated with mechanical replacement while maintaining optimal deburring performance for each wheel variant.
4Extent of automation
If a complex mechanism with multiple motors and adjustment systems is implemented, then the automation level and adaptability improve, but the device complexity and initial investment increase
Solution Approach 1:
The patent replaces manual mechanical adjustment mechanisms with automated electronic control systems. Instead of using complex mechanical linkages, gears, and manual positioning devices, the system employs electronic sensors to detect wheel dimensions and uses motorized actuators with closed-loop control to automatically position and adjust brush parameters. This substitution of mechanical systems with electronically controlled systems reduces the physical complexity of the mechanism while achieving higher automation levels and more precise control.
Data Source
AI summary
Disclosed is a deburring device for a back cavity of a wheel, composed of a machine frame, a clamping and rotating system, a rising and falling translation system and brush units. Jaws clamp a wheel on a roller way, upper cylinders enable the wheel to rise through four upper guide posts, and a first servo motor enables the wheel to move to upsides of conical sleeves through a second gear rack and a second gear; the upper cylinders enable the wheel to fall, and outer sides of the four jaws are in fit with the conical sleeves; a second motor enables the wheel to rotate in a clamped state; a first motor drives a bottom plate and a brush system to rotate in a circumferential direction through a first synchronizing belt; a second servo motor drives a first brush to rotate, a third servo motor drives a second brush to rotate, and brush hairs of the two brushes apply brushing forces of different directions to a back cavity of the wheel; a direction of rotation of the wheel is opposite to that of the brush system; and lower cylinders enable the brush system to rise through lower guide posts, and the brush system can carry out deburring when the brush system is in contact with the back cavity of the wheel.