Angular Bolt Gear Mechanism With Flattened Limbs for Lower Power Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bolt-type angular gear mechanisms suffer from low efficiency due to high power losses such as shear, splash, suction, and compression losses during the rotational movement of angular bolts.
Innovation Solution
The design incorporates angular bolts with flattened portions, conical regions, and cutouts or pockets to reduce friction and improve lubrication, along with a conical or cylindrical shape to enhance the transmission of torque and reduce power losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If angular bolts with cylindrical limbs are used in bolt-type angular gear mechanisms, then the structural simplicity is maintained, but the power losses (shear, splash, suction, and compression losses) are high resulting in low efficiency
Solution Approach 1:
The patent applies local quality by modifying only specific regions of the angular bolt limbs rather than changing the entire structure. The flattened portions are introduced at specific locations where the limbs interact with the bolt receptacles, while the rest of the limb structure remains cylindrical to maintain simplicity. This localized modification reduces power losses without significantly increasing overall structural complexity.
Solution Approach 2:
The patent changes the geometric parameters of the angular bolt limbs by introducing flattened portions with specific dimensions and positions. These parameter changes affect the contact characteristics between the bolts and receptacles, reducing friction and power losses. The flattened portions have defined lengths, widths, and positions that are optimized to minimize energy losses during operation.
2Power
If the limbs of angular bolts continuously enter and exit bolt receptacles during rotational movement, then the torque transmission between angled shafts is achieved, but friction and power losses increase
Solution Approach 1:
The flattened portions are strategically positioned on the limbs to optimize the interaction with bolt receptacles during rotation. These localized modifications reduce friction during the entry and exit phases while maintaining effective torque transmission during the engaged phase. The flattened regions create better contact conditions that reduce energy losses without compromising the power transmission function.
3Reliability
If conventional angular bolts are used without flattened portions, then the manufacturing process is simpler, but the lubrication effectiveness and efficiency are reduced
Solution Approach 1:
The flattened portions are introduced as localized features on the limbs rather than redesigning the entire bolt structure. This approach improves lubrication effectiveness by creating specific contact surfaces that better retain and distribute lubricant, while adding minimal complexity to the manufacturing process. The flattened regions can be incorporated into existing manufacturing workflows with relatively simple modifications.
Data Source
AI summary
A bolt-type angular gear mechanism (1), having angular bolts (3) each with two limbs, which are angled in relation to each other, a first bolt carrier (11), which is rotatable about a first axis (13) and has first bolt receptacles (15), in each of which a first limb (5) of one of the angular bolts (3) is at least partially received, and a second bolt carrier (21), which is rotatable about a second axis (23), which is different from the first axis (13), and has second bolt receptacles (25), in each of which a second limb (7) of one of the angular bolts (3) is at least partially received, so that the first bolt carrier (11) and the second bolt carrier (21) are connected by means of the angular bolts (3), wherein the limbs of the angular bolt (3) have a flattened portion (39), wherein the flattened portion extends in the longitudinal direction of the limb.