Dual Gear Train Transmission With Axial Clamping for Zero Backlash
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Solution Overview
Problem
Existing gearboxes and actuators suffer from backlash, which affects their performance characteristics and precision in mechanical adjustments.
Innovation Solution
A dual gear train system is introduced, with a clamping device that applies axial force to reduce or eliminate backlash, allowing for parallel transmission of forces and torques, and a position encoder system using an absolute encoder to enhance precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single gear train is used, then the device complexity is low, but backlash occurs which reduces measurement precision and manufacturing precision
Solution Approach 1:
The patent combines two gear trains in parallel between the same input and output shafts, creating a redundant transmission path. This merging of transmission paths allows the system to eliminate backlash through the interaction between the two gear trains while maintaining the same overall gear ratio, directly resolving the contradiction between precision improvement and complexity increase.
Solution Approach 2:
The patent introduces a movable gear element that can shift axially between two positions, engaging alternately with two different gear trains. This dynamic switching mechanism allows the system to maintain zero backlash by ensuring that at least one gear train is always under preload, resolving the backlash-precision contradiction while managing complexity through controlled movement rather than static dual engagement.
2Manufacturing precision
If a clamping device is added to eliminate backlash, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent employs spring elements that pre-load the gear trains before operation begins, creating a cushioning effect that maintains constant contact between gear teeth. This beforehand cushioning ensures that backlash is eliminated from the start of operation, improving manufacturing precision while the spring mechanism adds minimal complexity compared to active clamping devices.
Solution Approach 2:
The movable gear element automatically shifts positions based on the direction of torque application, engaging the appropriate gear train that is pre-loaded in that direction. This self-service mechanism eliminates the need for external actuators or complex control systems to manage the clamping, as the system self-regulates to maintain zero backlash through its own operational dynamics.
3Measurement precision
If an absolute encoder is used for position control, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent replaces mechanical end-stop based position control with an absolute encoder system that provides digital position information. This substitution eliminates the need for mechanical reference points and complex mechanical feedback mechanisms, improving measurement precision while the electronic encoder system manages complexity through non-contact sensing and digital signal processing.
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 dual gear train system reduces backlash, improving the operating characteristics and precision of mechanical adjustments, enabling accurate position control without mechanical end stops.
Implementation Method 1
the clamping device engages with a spring-loaded ball
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a transmission (5), it is proposed to form two parallel and separate gear trains (10, 12) between an input gear section (6) and an output gear section (8). (Fig. 2)