Free-Rotating Synchronizer Pinion for High-Load Rollers
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Solution Overview
Problem
Synchronized rollers face issues with radial compression leading to deformation of the rolling cylindrical surface, altering speed and angular displacement, causing abnormal loads on pinions and racks, resulting in premature wear and energy losses due to friction, and increasing manufacturing complexity and cost.
Innovation Solution
The synchronized roller with freewheels features a central body with a smooth shaft and pinion axial stop and guide means, allowing the synchronization pinion to rotate freely and accommodate differences in angular speed between the rolling surface and pinions, reducing load on teeth and enabling simpler, less expensive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the synchronized roller is subjected to high radial loads, then it can support heavy loads, but the rolling cylindrical surface deforms leading to altered speed and angular displacement
Solution Approach 1:
The roller is divided into functionally independent parts: the rolling cylindrical surface and the synchronization pinion are decoupled through a free rotation mechanism. This segmentation allows the rolling surface to deform under load without transmitting deformation to the pinion, maintaining synchronization precision while supporting heavy radial loads.
Solution Approach 2:
A free rotation mechanism acts as an intermediary between the rolling cylindrical surface and the synchronization pinion. This intermediary absorbs the deformation effects from radial loads, preventing them from affecting the angular displacement precision of the pinion while still allowing the roller to support heavy loads.
2Force
If the rolling cylindrical surface diameter is made larger to support heavy loads, then load capacity increases, but the speed of rotation must remain acceptable
Solution Approach 1:
The synchronization pinion is given freedom to rotate dynamically, allowing it to adjust its rotational speed independently from the rolling cylindrical surface. This dynamic adjustment capability enables the system to maintain acceptable rotation speeds even when the roller diameter is increased for heavy load support.
3Stability of the object's composition
If the pinions are rigidly attached to the rolling surface, then synchronization is maintained, but abnormal loads occur on the teeth under high radial compression
Solution Approach 1:
The rigid attachment between the rolling surface and pinion is segmented into two independently rotatable components. The free rotation mechanism creates a decoupling that maintains synchronization stability through gear engagement while preventing abnormal load transmission to the pinion teeth under radial compression.
4Ease of manufacture
If the rolling surface is kept perfectly circular, then manufacturing is simpler, but radial compression causes deformation leading to premature wear
Solution Approach 1:
The system segments the functions of load-bearing and synchronization, allowing the rolling surface to be simply manufactured as a circular cylinder while the free rotation mechanism protects against deformation effects. This enables the use of simpler manufacturing processes without compromising roller durability under radial compression.
Data Source
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AI summary
The invention relates to a synchronized free-wheel roller (1) comprising a central body (2) having an outer cylindrical rolling surface (3) intended to roll between two raceways bordered by synchronizer racks or synchronizer rings, each end (9) of the body (2) having a smooth shaft (10) about which a synchronizer pinion (8) can rotate freely, said shaft (10) including axial pinion-stop means (12) that prevent the pinion (8) from leaving the shaft (10), while axial roller-guiding means (13) bear on the central body (2) and on the raceways in order to maintain the outer cylindrical rolling surface (3) approximately centred on the raceways.