Modular Coaxial Gear Coupling for Concentric High-Torque Reduction
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Solution Overview
Problem
Existing planetary gear structures face challenges with high machining complexity, potential waste due to integrated sun gear and transmission shaft design, sophisticated assembly processes, and issues with accuracy and concentricity, leading to noise and inefficiency in torque transmission.
Innovation Solution
A coupling structure allowing separate shaft and tube components to couple axially and radially, with a modularized coaxial gear train reduction mechanism that enhances coupling strength, assembly ease, and concentricity, reducing vibration and noise while improving transmission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sun gear is formed as an integrated one-piece structure on the transmission shaft through machining, then the coupling strength between the sun gear and transmission shaft is increased, but the machining complexity of the transmission shaft is increased
Solution Approach 1:
The patent divides the integrated sun gear-transmission shaft structure into separate components: the transmission shaft and the sun gear are manufactured independently and then connected through a coupling structure. This segmentation reduces the machining complexity of the transmission shaft while maintaining the necessary coupling strength through dedicated coupling features.
2Strength
If the sun gear is formed as an integrated one-piece structure on the transmission shaft, then the coupling strength is increased, but the waste increases when parts need replacement or repair
Solution Approach 1:
By separating the sun gear from the transmission shaft through a modular coupling design, the patent enables independent replacement of the sun gear without discarding the transmission shaft. This reduces material waste when repair or replacement is needed, while the coupling structure maintains sufficient strength for high-torque applications.
3Ease of manufacture
If the reduction mechanism is assembled piece by piece on the transmission shaft and sun gear, then the assembly process becomes sophisticated and time-consuming, but the manufacturing flexibility is improved
Solution Approach 1:
The patent segments the planetary gear system into modular components that can be assembled in a standardized sequence using the coupling structure as a reference framework. This modular approach streamlines the assembly process while maintaining flexibility for different configurations.
Solution Approach 2:
The coupling structure is designed with pre-defined positioning features and connection interfaces that guide the assembly process. By preparing the coupling structure in advance with precise geometric features, subsequent assembly steps are simplified and accelerated, reducing overall assembly time while maintaining manufacturing flexibility.
4Ease of manufacture
If the reduction mechanism is assembled piece by piece, then the assembly process becomes complex, but the concentricity and assembly accuracy are affected
Solution Approach 1:
The coupling structure incorporates pre-designed positioning features, precision bores, and alignment elements that establish accurate concentricity before final assembly. By preparing these precision features in advance during coupling structure manufacturing, subsequent assembly operations inherit this accuracy, ensuring proper concentricity of the sun gear with the transmission shaft while maintaining assembly flexibility.
Data Source
AI summary
A coupling structure includes a shaft, a tube, and a connection assembly. An end of the shaft is formed with a plurality of axial insertion troughs extended in an axial direction and arranged in an alternate manner. The tube includes a penetration-axle hole formed in a center thereof and corresponding to the penetration-axle section of the shaft. A plurality of radial insertion troughs, in the form of a recessed surface, are formed in an inner circumferential surface of the penetration-axle hole of the tube. The connection assembly includes a coupling block that has an outer circumference formed with a plurality of radial insertion blocks corresponding to the radial insertion troughs of the tube and a plurality of axial insertion blocks corresponding to the axial insertion troughs of the shaft, so that a fastening member may be used to selectively fasten the coupling block between the shaft and the tube.