Asymmetrical Sprocket Teeth for Low-Wear Thrust Chains
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Solution Overview
Problem
Existing thrust chain technologies face challenges with high noise, vibration, and wear, particularly when handling large loads over long strokes, and require frequent maintenance, limiting their application in industries that demand high performance and efficiency.
Innovation Solution
A thrust chain device featuring a straight and curved portion with a driving sprocket that engages the chain through involute contact surfaces, where the sprocket is positioned between the curved and straight portions, allowing for prolonged tooth contact and distributing the load across multiple teeth, reducing wear and noise, and increasing the linear bearing capacity while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional thrust chain technology is used, then the chain can move large loads over long strokes, but it produces high noise and vibration with frequent wear requiring maintenance
Solution Approach 1:
The tooth is segmented into multiple contact surfaces (front surface, rear surface, and side surfaces) that engage with different portions of the chain rollers. This segmentation distributes the load across multiple teeth simultaneously, reducing the impact force and vibration on any single tooth-chain interface, thereby lowering noise and vibration while reducing wear on individual components
Solution Approach 2:
The tooth profile is designed with asymmetric geometry where the front surface and rear surface have different angles and curvature radii. The front surface has a larger curvature radius and different engagement angle compared to the rear surface, optimizing the contact mechanics for both the straight and curved portions of the chain, which reduces impact forces and improves operational smoothness
2Volume of stationary object
If the sprocket contacts only the straight portion of the chain, then the design remains compact, but the load distribution is insufficient
Solution Approach 1:
The tooth engagement extends beyond the traditional single-plane contact by utilizing both the front and rear surfaces of each tooth to engage with chain rollers. This multi-dimensional engagement allows the sprocket to effectively increase its load-distributing capability without increasing its radial or axial dimensions, maintaining compactness while improving load distribution
3Reliability
If the contact angle between tooth and chain is increased, then wear is reduced, but the sprocket complexity increases
Solution Approach 1:
Different portions of the tooth profile have different geometric properties optimized for their specific function. The front surface has a larger curvature radius for engaging the straight portion of the chain, while the rear surface has a smaller curvature radius for the curved portion. This local differentiation of geometric quality achieves extended contact angles and improved wear resistance without requiring complex overall tooth geometry
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 solution significantly reduces noise, vibration, and wear, enhances energy efficiency, and extends the service life of the chain by distributing the load and maintaining a compact design, enabling the chain to handle higher loads with reduced maintenance needs.
Implementation Method 1
a driving sprocket (1) having teeth (2) engaging the thrust chain (10), the driving sprocket (1) being in contact with the thrust chain (10) by involute contact surfaces
Data Source
AI summary
Thrust chain device, includes a thrust chain with a straight portion along an axis and a curved portion, and links hinged on shafts, a chain guide, a driving sprocket with chain interlocking teeth, the sprocket being in contact with the chain via contact surfaces in the shape of an involute of a circle, the contact surfaces belonging to the teeth, a tooth engaging with the chain while defining a line of action having an angle with the shaft of the straight portion of between −10° and 10°, the sprocket in contact with the straight portion and not the curved and is mounted such that it can rotate on a shaft on the side of the chain opposite the curved portion's center of curvature, the contact surfaces including a convex front surface directed towards the straight portion and a rear surface directed towards the curved portion when the tooth is interlocking.