Double Reduction Gear Train With Anti-Rotation Ring Gear Assembly
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Solution Overview
Problem
Existing tools, such as ratchet wrenches, face difficulties in assembly due to complex internal gear assemblies and are prone to rotation failure over time, leading to inefficiencies and potential damage from repeated use or drops.
Innovation Solution
A double reduction gear train design with sequential gear trains and recessed gear carrier assemblies that utilize similar components to simplify assembly and prevent rotation relative to the housing, using protrusions and recesses to secure the gear train in place, thereby reducing the need for additional coupling parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional internal gear assemblies are used, then torque transfer is achieved, but assembly complexity increases and rotation failure risk increases
Solution Approach 1:
The patent combines the gear carrier and planet gear support functions into a single integrated component. The gear carrier assembly includes internal gears that serve dual purposes: supporting planet gears and preventing rotation of the entire gear train relative to the housing, eliminating the need for separate rotation prevention mechanisms
Solution Approach 2:
The internal gears of the gear carrier assemblies perform multiple functions simultaneously: they support the planet gears, transfer torque between stages, and prevent rotation of the gear train through engagement with recesses in the housing. This multi-functionality reduces the total number of components needed
2Reliability
If additional coupling parts are used to prevent rotation, then rotation resistance improves, but device complexity increases
Solution Approach 1:
The patent merges the rotation prevention function into the existing gear carrier structure. Recesses are formed directly in the housing that engage with protrusions on the gear carrier assemblies, eliminating the need for separate coupling parts or rotation prevention mechanisms
Solution Approach 2:
The gear carrier assemblies are designed to self-restrain rotation through the engagement of recesses in the housing with corresponding features on the gear carriers. The structure serves itself to prevent rotation without requiring additional external components
3Power
If complex internal gear assemblies are used, then torque transfer capability is achieved, but manufacturing and assembly difficulty increases
Solution Approach 1:
The gear train is divided into two separate reduction stages, each with its own gear carrier assembly and planet gears. This segmentation allows each stage to be manufactured and assembled independently, simplifying the overall manufacturing process while achieving the required torque multiplication
Solution Approach 2:
The patent uses two sequential gear trains with different gear ratios to achieve the target reduction. By changing the parameters of each stage rather than using a single complex stage, the design becomes more manufacturable and easier to assemble
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
This design simplifies the assembly and manufacturing of tools, reduces gear rotation, and ensures effective torque transfer to the ratchet mechanism while preventing unwanted rotation of the gear train, enhancing durability and operational efficiency.
Implementation Method 1
a first ring gear including a first protrusion extending from an outer surface of the first ring gear, wherein the first protrusion is adapted to engage the recess and resist rotation of the first ring gear with respect to the ratchet housing
Implementation Method 2
a first gear train adapted to receive torque from the motor, and a second gear train sequentially coupled to the first gear train. The second gear train is adapted to transfer the torque from the first gear train to the drive unit
Data Source
AI summary
A tool with two sequential gear trains and gear carrier assemblies adapted to be recessed into internal gears. The internal gear assembly also prevents rotation of the internal gear assembly relative to a housing of the tool. For example, the internal gear assembly can include a first gear train and second gear train sequentially coupled to the first gear train, wherein a first ring gear and first planet gears of the first gear train are substantially similar to a second ring gear and second planet gears of the second gear train.