Extruded Ring Gear Production for Flexible Planetary Gear Specs
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Solution Overview
Problem
The existing methods for producing ring gears for planetary gears, such as injection molding, are costly and time-consuming, especially for small series production, as they require new molds for each specification, leading to high manufacturing costs and time inefficiencies.
Innovation Solution
A method utilizing an extrusion process to produce a ring gear, where an endless profile is pressed out and cut to a predetermined length, allowing for internal gearing formation directly, with the option to adjust the number of teeth and use laser cutting to minimize post-processing and reduce production costs, using plastic materials like PBT, POM, or PEEK for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding is used to produce ring gears, then manufacturing precision and reliability are improved, but manufacturing cost and production time increase due to the need for new molds for each specification
Solution Approach 1:
The patent applies universality by creating a single mold that can produce multiple ring gear specifications through adjustable cutting positions. Instead of requiring separate molds for each specification, the universal mold can accommodate different cutting lengths and tooth configurations, allowing one mold to serve multiple production purposes and reducing overall manufacturing cost.
Solution Approach 2:
The patent implements dynamics by making the cutting position adjustable during the molding process. The cutting device can be positioned at different locations along the extruded profile to create ring gears with different numbers of teeth and specifications. This dynamic adjustment capability eliminates the need for static, dedicated molds for each specification.
2Manufacturing precision
If injection molding is used to produce ring gears, then manufacturing precision is improved, but production time increases due to mold manufacturing and setup
Solution Approach 1:
The universal mold design allows a single mold to produce multiple ring gear specifications by adjusting the cutting position. This eliminates the time required to manufacture and switch between multiple dedicated molds, significantly reducing production time while maintaining manufacturing precision through controlled cutting operations.
Solution Approach 2:
The patent applies preliminary action by pre-configuring the mold with adjustable cutting mechanisms that can be positioned for different specifications before production begins. The extrusion process continuously produces profiles that are then cut to specific lengths, allowing rapid production changes without retooling time.
3Manufacturing precision
If new molds are manufactured for each ring gear specification, then manufacturing precision for that specification is improved, but device complexity and initial cost increase
Solution Approach 1:
The patent reduces device complexity by replacing multiple specification-specific molds with a single universal mold system. The universal mold incorporates adjustable cutting mechanisms that can be repositioned to produce different ring gear specifications, simplifying the overall mold inventory and reducing the complexity of managing multiple dedicated molds.
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 method enables the simple and cost-effective production of ring gears with adjustable specifications, reducing manufacturing time and eliminating the need for multiple molds, allowing for quick production of various configurations from a single endless profile, and enabling a modular system with different ring gears for planetary gears.
Implementation Method 1
a continuous profile is produced by an extrusion process
Implementation Method 2
the continuous profile is cut to a predetermined length
Data Source
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AI summary
The problem addressed by the invention is that of producing a ring gear (10) for a planetary gearing (1), which has hitherto not been adequately solved. In particular, high costs in the event of requirement changes are disadvantageous. This problem is solved by means of a method for producing a ring gear (10) for a planetary gearing (1), wherein an endless profile (16) is produced by means of an extrusion process and the endless profile (16) is then cut to a predefined cut length (C, C1, C2, C3) in order to form a ring gear body (12, 12', 12'', 12''').