Balance Beam Gearbox for Even Load Sharing in Parallel Shafts
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Solution Overview
Problem
Gearboxes with parallel load paths experience uneven load distribution due to manufacturing tolerance stack-ups, leading to accelerated component degradation and reduced longevity.
Innovation Solution
A gearbox system with a balance beam that transfers loads between intermediate shafts with identically sized helical gears, using axial thrust bearings and a fulcrum to balance loads, thereby distributing torque more evenly and reducing component wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If parallel load paths are used in gearbox design, then component load can be managed and torque capacity increased, but manufacturing tolerance stack-up causes uneven load distribution leading to accelerated degradation of components in one load path
Solution Approach 1:
A balance beam is introduced as an intermediary component between the two parallel intermediate shafts. The balance beam couples the shafts together and actively transfers loads between them, serving as a mediator that equalizes the load distribution. This allows the system to maintain high torque capacity through parallel paths while ensuring reliable, even load sharing across all components.
2Manufacturing precision
If parallel load paths with identically sized gears are used, then load distribution can be improved, but manufacturing tolerance stack-up still causes one load path to take the bulk of the load
Solution Approach 1:
The balance beam creates a dynamic load sharing mechanism. Instead of relying on static, identical gear dimensions, the system uses the flexible coupling of the balance beam to dynamically adjust and equalize loads between the two intermediate shafts during operation. This dynamic adjustment compensates for manufacturing tolerances and ensures even load distribution despite gear size variations.
3Reliability
If a balance beam is added to transfer loads between intermediate shafts, then load distribution is improved and component wear is reduced, but device complexity increases
Solution Approach 1:
The balance beam serves multiple functions simultaneously: it acts as a structural support element, a load transfer mechanism, and a balancing device. By making the balance beam multi-functional, the patent reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving improved load distribution and reduced component wear.
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 effectively increases gearbox longevity by evenly distributing loads, reducing component wear, and simplifying manufacturing processes, making the gearbox less susceptible to degradation and more reliable.
Implementation Method 1
a balance beam that transfers loads between the first intermediate shaft and the second intermediate shaft
Implementation Method 2
a first axial thrust bearing coupled to a first end of the balance beam and the first intermediate shaft and a second axial thrust bearing coupled to a second end of the balance beam and the second intermediate shaft
Data Source
AI summary
Systems and methods for a gearbox. The gearbox system, in one example, includes an input shaft with a first helical gear coupled thereto, a first intermediate shaft with a second helical gear coupled thereto and meshing with the first helical gear and a second intermediate shaft with a third helical gear coupled thereto and meshing with the first helical gear. The gearbox system further includes a balance beam that transfers loads between the first intermediate shaft and the second intermediate shaft.