Synchronized Dual Drive Gear Assembly Torque Distribution
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Solution Overview
Problem
Existing gear assemblies face challenges in withstanding high loads in limited size applications, particularly in industrial and military-grade pipeline control valves, due to size limitations and complex skew-axis arrangements that increase machining and assembly complexities.
Innovation Solution
A gear assembly comprising an actuation gear with first gear teeth and plural separate pinion bodies with second gear teeth, where the pinion bodies rotate around parallel axes perpendicular to the actuation axis, allowing for increased torque capacity and simplified integration by reducing the need for non-orthogonal and non-parallel axis arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single pinion engages multiple surfaces of an enveloping gear in a skew-axis arrangement to increase power and torque output, then torque capacity is improved, but device complexity and manufacturing difficulty increase due to non-orthogonal and non-parallel axis arrangements
Solution Approach 1:
The single pinion is divided into multiple separate pinions (first pinion and second pinion), each engaging a different surface of the enveloping gear. This segmentation allows each pinion to have a simpler, more standard axis arrangement while collectively achieving the required torque capacity through distributed engagement across multiple gear surfaces.
Solution Approach 2:
The invention transitions from a skew-axis arrangement (non-orthogonal, non-parallel) to a multi-dimensional parallel axis arrangement. Multiple pinions are positioned at different locations around the enveloping gear, all rotating on parallel axes, thereby solving the complexity issue while maintaining torque capacity through spatial distribution.
2Strength
If larger gears are used to increase the area on gear teeth to withstand high forces, then load-bearing capacity is improved, but size limitations of the gear assembly are violated
Solution Approach 1:
The load-bearing function is segmented across multiple pinions instead of concentrating it in a single large gear. Each pinion engages a different surface of the enveloping gear, distributing the high forces across multiple contact points. This allows the gear assembly to withstand high loads while maintaining a compact size, as the load is shared rather than requiring a single oversized component.
Solution Approach 2:
The gear assembly uses a composite configuration of multiple pinions and enveloping gear surfaces working together. This composite structure achieves high load-bearing capacity through the combined effect of multiple engagement points, analogous to how composite materials achieve enhanced properties through material combination, while keeping individual components small and compact.
3Power
If skew-axis gear arrangements are used to increase power output, then torque capacity is improved, but ease of manufacture deteriorates due to atypical housing and mounting features requiring complex machining and fabrication
Solution Approach 1:
The complex skew-axis arrangement is segmented into multiple simple parallel-axis pinion-gear engagements. Each pinion can be manufactured and assembled independently using standard machining processes, eliminating the need for complex skew-axis housing and mounting features. This segmentation dramatically simplifies manufacturing while maintaining the torque multiplication function through distributed engagement.
Solution Approach 2:
Instead of using a single complex skew-axis pinion-gear arrangement, the invention inverts the approach by using multiple simple parallel-axis pinions. This inversion transforms the manufacturing problem from complex skew-axis machining to simple parallel-axis machining, significantly improving ease of manufacture while achieving the same or better torque output through multiple engagement points.
Data Source
AI summary
A gear assembly includes an actuation gear and plural separate pinion bodies. The actuation gear has first gear teeth on one or more surfaces of the gear and is configured to rotate around an actuation axis of rotation. The pinion bodies have second gear teeth configured to mesh with the first gear teeth of the actuation gear in plural separate mesh zones of the actuation gear. Each of the plural separate pinion bodies are configured to be rotated about respective pinion axes of rotation to cause rotation of the actuation gear around the actuation axis of rotation.