Configurable Idler Gear Mount for Multi-Ratio Gearboxes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gearboxes require distinct housings for different gear ratios, necessitating separate manufacturing and component changes, which is inefficient and cumbersome, especially in large industrial applications.
Innovation Solution
A gearbox design featuring a reconfigurable mount with an eccentric bushing and fastener system that allows the same housing to accommodate different gear ratios by altering the offset between the input and idler gears, using a single housing for multiple gear configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distinct housings are manufactured for different gear ratios, then the gear ratio can be accurately accommodated, but the manufacturing complexity and cost increase
Solution Approach 1:
The idler gear mount is made adjustable through an eccentric bushing mechanism that allows the mount position to be dynamically changed between different predefined locations, enabling the same housing to accommodate different gear ratios without requiring distinct housings for each configuration
Solution Approach 2:
The offset distance between the input shaft axis and idler gear axis is changed by repositioning the idler gear mount to different locations on the housing, thereby changing the gear ratio parameter while using the same housing structure
2Adaptability or versatility
If the idler gear placement is changed for new applications, then the gear ratio can be adjusted, but the housing must be remanufactured
Solution Approach 1:
The housing is designed with multiple predefined mount locations that can accommodate different idler gear positions, making the housing universal for multiple gear ratio configurations and eliminating the need to remanufacture the housing for different applications
Solution Approach 2:
The housing includes discrete, predefined locations for mounting the idler gear, allowing the system to be segmented into configurable positions that can be selected based on the required gear ratio without redesigning the entire housing
3Reliability
If multiple housings are maintained for different gear ratios, then each configuration is optimized, but the device complexity increases
Solution Approach 1:
Multiple housing variants designed for different gear ratios are merged into a single housing design that incorporates all necessary mount locations, reducing the number of housing types from multiple to one while maintaining configuration optimization through selective mounting
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
Enables flexible gear ratio adjustment without requiring new housings, simplifying manufacturing and component changes, particularly beneficial in large industrial applications where space and component handling are challenging.
Implementation Method 1
The eccentric bushing is rotatable about the mount axis to alter an offset between the input axis and the idler gear axis
Data Source
AI summary
A gearbox includes a housing, input shaft, and a geartrain. An input gear fixed to the input shaft is rotatable about an input axis. An idler gear is rotatable about an idler gear axis and supported by a mount. Output gear(s) are rotated from the idler gear. The mount includes a mount pin extending along a mount axis through the idler gear and an opening in the housing, and an eccentric bushing positioned around the mount pin and centrally within the idler gear. The eccentric bushing is rotatable about the mount axis to alter an offset between the input axis and the idler gear axis. A fastener can lock a position of the bushing in relation to the housing. The fastener is engageable in a first/second hole of the housing to accommodate a first/second gear ratio between the input gear and the output gear(s).