Face Gear Tooth Flank Path of Contact Correction
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Solution Overview
Problem
Face gears produced by die forming exhibit non-uniform rotation when misaligned during assembly, leading to unsmooth handle rotation and increased assembly time due to rotational feeling deterioration.
Innovation Solution
A method to derive and process the path of contact on face gear tooth flanks by positioning the pinion gear, calculating rotational errors, and determining a curve connecting contact positions to minimize fluctuation errors, even with assembly dimensional errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If die forming is used to mass produce face gears, then productivity is improved and production cost is reduced, but manufacturing precision deteriorates due to non-uniform rotation when misaligned during assembly
Solution Approach 1:
The invention modifies the tooth flank shape parameters of the face gear by deriving a corrected path of contact that compensates for assembly misalignment. The tooth flanks are generated with adjusted curvature and contact angles based on calculated transmission errors, enabling the gear to maintain uniform rotation even when assembly dimensions deviate from nominal values.
Solution Approach 2:
The invention performs preliminary correction of the tooth flank geometry during the manufacturing stage to anticipate and compensate for potential assembly misalignments. By pre-calculating the path of contact considering possible dimensional errors and shaping the tooth flanks accordingly, the system eliminates the need for post-assembly adjustments and ensures smooth operation despite manufacturing tolerances.
2Manufacturing precision
If traditional cutting methods are used to generate tooth flanks, then manufacturing precision is maintained, but productivity deteriorates due to time-consuming assembly adjustment
Solution Approach 1:
The invention enables the face gear to self-compensate for assembly misalignment through its specially designed tooth flank geometry. The corrected path of contact automatically adjusts the contact points and force distribution to maintain uniform transmission, eliminating the need for manual alignment adjustments and reducing assembly time while preserving rotational uniformity.
3Device complexity
If the path of contact is not corrected for assembly errors, then device complexity is reduced, but reliability deteriorates due to non-uniform rotation and rotational feeling deterioration
Solution Approach 1:
The invention applies localized quality changes to specific regions of the tooth flanks where contact occurs. The path of contact correction focuses on modifying the contact zone geometry while leaving other portions of the gear structure unchanged, thereby improving rotational smoothness and reliability without significantly increasing overall device complexity.
Data Source
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AI summary
A method of deriving a path of contact of a face gear with a pinion gear includes positioning the pinion gear, shifting the pinion gear from either towards or away from the face gear along a rotational axis, deriving a first relationship between a rotational angle of the pinion gear and a fluctuation error angle, deriving second and third relationship by shifting the first relationship in either way for 360 degree divided by the number of the gear teeth, deriving a first point which the first and second relationships share and a second point which the first and third relationships share, deriving a third point, at which the fluctuation error is the same as the first and second points, between the first and second points, and determining a curve line on tooth flanks of the gear teeth on the basis of the first, second, and third points.