Double Ratchet Transmission Module for Reduced Jolting
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Solution Overview
Problem
Existing force transmission modules, particularly those using ratchet systems, face limitations in mechanical durability and are costly to implement, as they often result in jolting of toothed wheels, which reduces their lifespan and increases wear, and are not easily adaptable for frequent operations required by renewable energy systems.
Innovation Solution
A double ratchet transmission module with two cams actuating the ratchets alternately, allowing continuous rotation of the toothed wheel with reduced jolting, alleviating the force on the transmission module, and utilizing a simpler design with fewer parts, making it more economical and durable for at least 30,000 cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ratchet system is used to rotate the toothed wheel, then the toothed wheel can be rotated in the direct direction, but jolting occurs during rotation which reduces mechanical durability
Solution Approach 1:
The single ratchet system is segmented into two ratchets (first ratchet and second ratchet) that operate alternately. Each ratchet handles a portion of the rotation cycle, with the first ratchet acting during a first angular course and the second ratchet acting during a second angular course. This segmentation distributes the mechanical stress and eliminates continuous jolting by ensuring smooth transition between ratchets.
Solution Approach 2:
The two ratchets operate in a periodic alternating manner throughout the rotation cycle. The first ratchet is activated during the first angular course while the second ratchet is activated during the second angular course, creating a continuous periodic action that maintains constant force transmission without interruption or jolting.
2Object-generated harmful factors
If a planetary gear train is used instead of ratchet systems, then jolting is eliminated, but the device becomes more complex and costly
Solution Approach 1:
The complex planetary gear train is extracted and replaced with a simplified ratchet-based mechanism. The invention takes out the unnecessary complexity of multiple gears, carriers, and sun gears, retaining only the essential ratchet components needed to achieve smooth rotation. This extraction maintains the benefit of eliminating jolting while dramatically reducing the number of parts.
Solution Approach 2:
The invention uses simple, inexpensive ratchet components instead of precision-manufactured planetary gears. The ratchets are easier and cheaper to manufacture with standard machining processes, eliminating the need for high-precision gear cutting. While individual ratchets may wear, they are simple to replace compared to the complex planetary gear assembly.
3Reliability
If multiple ratchets are used to drive the toothed wheel, then mechanical durability is improved, but the force required to actuate the ratchets increases wear on the transmission module
Solution Approach 1:
The two ratchets operate in periodic alternation, with each ratchet engaged for only a portion of the rotation cycle (first angular course and second angular course respectively). This periodic engagement reduces the cumulative wear on each individual ratchet and the toothed wheel compared to continuous engagement of multiple ratchets, while still providing the durability benefits of a multi-ratchet system.
Solution Approach 2:
The alternating activation of the two ratchets ensures continuous force transmission to the toothed wheel without interruption. The first ratchet acts during its angular course, then the second ratchet takes over during its angular course, maintaining continuous useful action. This continuity eliminates gaps in force transmission while distributing the wear across two ratchets operating in sequence.
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 module achieves enhanced mechanical durability and reduced wear by ensuring continuous force transmission without jolting, extending the module's lifespan and reducing production and implementation costs, while allowing for manual actuation and efficient energy accumulation.
Implementation Method 1
at least two cams, which are connected immovably to one another, known respectively as the first cam and second cam, and are designed to actuate respectively the first ratchet according to a first angular course around an axis YY′ of the first cam, and the second ratchet according to a second angular course around the axis YY′ of the second cam
Implementation Method 2
a first ratchet and a second ratchet, each of the first and second ratchets being designed such as, when it is actuated, to rotate the toothed wheel in a direction, known as the direct direction, around the main axis, by support of the ratchet concerned against a tooth of the toothed wheel
Data Source
AI summary
A module for transmission of a force including two toothed wheels which are connected to a main shaft; a first ratchet holder and a second ratchet holder which are provided with a first ratchet and a second ratchet, and are designed such, when they are actuated, to rotate the toothed wheels by support of the ratchet concerned against a tooth of the toothed wheel; a first cam and a second cam, which are designed to actuate respectively the first ratchet according to a first angular course around an axis YY′ of the first cam, and the second ratchet according to a second angular course around the axis YY′ of the second cam, which is different from the first angular course.