Sheet Metal Drive Disk Assembly for Inclined Roller Support
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Solution Overview
Problem
The existing frictional drive units for inverted pendulum vehicles face manufacturing complexity and increased costs due to the need for multiple bearing walls and slots, which are difficult to form and assemble effectively.
Innovation Solution
The drive disks are designed using two sheet metal members with radially extending arm parts that support rollers, allowing for easy formation and assembly, with the rollers being inclined to each other and supported by alternating arm parts to stabilize their position and facilitate manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bearing walls are prepared as separate members and assembled to the base, then the base can support drive rollers, but the number of operations increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the bearing wall function into the slot structure itself. The slots are formed directly in the base with inclined side walls that serve as bearing surfaces for the drive rollers, eliminating the need for separate bearing wall components. This integration reduces the total number of parts and assembly operations while maintaining the roller support capability.
2Reliability
If bearing walls and slots are arranged in different directions, then roller support is enabled, but it is difficult to form these elements and cost increases
Solution Approach 1:
The bearing wall function is merged with the slot structure. The slots are formed with inclined side walls that directly provide the bearing surface for drive rollers. This integration allows both the slot formation and bearing surface creation to be accomplished in a single manufacturing operation, eliminating the need for separate bearing wall components and reducing forming difficulty.
3Reliability
If multiple separate bearing walls are assembled to the base, then roller support is achieved, but manufacturing cost increases
Solution Approach 1:
The patent integrates the bearing wall function into the slot structure, eliminating the need for separate bearing wall components. The inclined side walls of the slots serve as bearing surfaces for the drive rollers, allowing the base to be manufactured as a single piece with all necessary support features, thereby reducing manufacturing cost.
4Ease of manufacture
If a single base structure is used to support rollers, then manufacturing is simplified, but the structure must accommodate inclined rollers efficiently
Solution Approach 1:
The patent applies local quality by creating slots with inclined side walls at specific locations in the base. The inclination angle of the slot side walls matches the inclination angle of the drive rollers, providing optimal contact and support. This localized geometric feature enables the single base structure to efficiently accommodate inclined rollers without requiring complex overall structural design.
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 manufacturing process of drive disks by using two sheet metal members to form the base that supports rollers, enabling stable and efficient production while maintaining the necessary structural integrity for the frictional drive unit.
Implementation Method 1
configured to rotate the main wheel around a central axis and an annular axis by applying a frictional force to the main wheel
Data Source
AI summary
Drive disks are configured to rotate a main wheel by applying a frictional force thereto. Each of the drive disks includes a base and a plurality of rollers. The base includes a first sheet metal member and a second sheet metal member. The first sheet metal member includes a first central part and a plurality of first arm parts. The second sheet metal member includes a second central part and a plurality of second arm parts. Each of the rollers has a first end and a second end. Each of the first arm parts includes a first supporting part and a second supporting part. Each of the second arm parts includes a third supporting part and a fourth supporting part. The first supporting part and the second supporting part are inclined to each other. The third supporting part and the fourth supporting part are inclined to each other.