Floating Gearbox Misalignment Accommodation
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Solution Overview
Problem
Existing gear transmission systems face challenges in accommodating large axial and angular misalignments between output and driven shafts, inducing torsional flexibility, and being suitable for coupling with snap-in driven shafts, which can result in errors and binding issues.
Innovation Solution
A floating gearbox design that includes an outer housing, slider plate, and inner gearbox assembly, allowing movement along intersecting axes, minimizing coupling forces, and featuring a rotary encoder for precise position sensing, enabling the gearbox to float freely and accommodate misalignments without inducing torsional flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard flexible couplings are used to join drive shafts, then slight axial and angular misalignment is accommodated, but large tolerance loops between output shaft and driven shaft cannot be accommodated
Solution Approach 1:
The gearbox housing is made movable relative to the driven shaft, allowing the entire gearbox to dynamically adjust its position to accommodate large misalignments. The housing can move axially and angularly to follow the driven shaft's position changes, while the internal gear mechanism maintains reliable power transmission.
Solution Approach 2:
The coupling system is divided into two independent functional parts: the internal gear transmission mechanism (providing reliable power transmission) and the movable housing (providing misalignment accommodation). This segmentation allows each part to optimize its specific function without compromising the other.
2Adaptability or versatility
If flexible shaft couplings are used to couple permanently fixed shafts, then coupling is achieved, but coupling with snap in driven shafts is not suitable
Solution Approach 1:
The gearbox housing is designed to move dynamically to accommodate both permanently fixed and snap-in driven shafts. This dynamic adjustment capability allows the system to adapt to different coupling types and installation methods while maintaining precise power transmission through the internal gear mechanism.
3Ease of operation
If flexible shaft couplings are used, then shaft connection is achieved, but torsional flexibility is induced into the system
Solution Approach 1:
The system separates misalignment accommodation (handled by the movable housing) from torsional rigidity (maintained in the internal gear mechanism). This segmentation allows the housing to move for alignment purposes while the gear train remains torsionally rigid, preventing encoder errors.
Solution Approach 2:
The flexible coupling mechanism is replaced with a movable housing that provides alignment adjustment without introducing torsional flexibility into the power transmission path. The housing movement substitutes for the function of flexible couplings while avoiding their harmful torsional effects.
4Adaptability or versatility
If the gearbox is made movable to accommodate misalignment, then tolerance loop is accommodated, but device complexity increases
Solution Approach 1:
The movable housing serves multiple functions simultaneously: it accommodates large misalignments, allows dynamic adjustment to driven shaft position, and maintains precise power transmission. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in overall system complexity.
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 floating gearbox effectively addresses misalignment and binding issues by allowing movement in two cardinal directions without restorative forces, ensuring precise positioning and minimizing off-axis forces, thus enhancing the accuracy and reliability of fluid flow control systems.
Implementation Method 1
a rotary encoder for sensing a rotational position of an output shaft of the helical gear
Data Source
AI summary
A floating gearbox includes an outer housing with first and second side walls opposite and spaced apart from each other and an inner gear assembly received within the outer housing. The inner gear assembly comprises an inner housing, a first gear member rotatably received within the inner housing, and a second gear member having an output shaft rotatably supported on the inner housing. A slider plate received within the outer housing has first and second pairs of axially aligned elongate openings, wherein the first and second pairs of elongate openings align with a first axis and a second axis, respectively. Pins on the first sidewall are received in the first pair of elongate openings to allow relative sliding movement between the outer housing and the slider plate along the first axis. The inner housing includes pins received in the second pair of elongate openings, allowing relative sliding movement between the inner housing and the slider plate along the second axis.