Gear Lock Control Device Under Load
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Solution Overview
Problem
Existing lock control devices for gear trains fail to unlock the drive gear when a large load is applied, as the lock gear cannot be operated effectively due to weight load on the gear tooth surface, preventing smooth unlocking.
Innovation Solution
A lock control device with a first drive means for linearly driving the lock gear and a second drive means for rotationally driving the drive gear, along with a control means that controls both to reverse polarity and direction, ensuring the lock gear can be disengaged even under load by utilizing a PI control system with adjusted gains for efficient unlocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large load is applied to the actuator, then the weight load is applied to the gear tooth surface at engagement position, but the lock gear cannot be operated and the gear may not be easily unlocked
Solution Approach 1:
The control device performs preliminary actions by operating the drive gear or lock gear in normal and reverse directions before the lock gear reaches the disengagement position. This preliminary operation creates conditions that facilitate subsequent unlocking by reducing engagement forces and preparing the gear train for smooth disengagement under load conditions
Solution Approach 2:
The control device applies periodic action by repeatedly operating the drive gear or lock gear in alternating normal and reverse directions during the unlocking process. This periodic operation helps to gradually reduce engagement forces and enables the lock gear to be pulled out successfully even when large loads are applied to the actuator
2Ease of operation
If the lock gear is directly moved by solenoid under load, then the structure is simple, but the gear may not be easily unlocked due to weight load on tooth surface
Solution Approach 1:
The control device introduces an intermediary mechanism by using the drive gear or lock gear as a mediator between the solenoid and the locking system. Instead of directly moving the lock gear under load, the intermediary operation of rotating the drive gear or lock gear in alternating directions facilitates the unlocking process by reducing engagement forces before the lock gear is pulled out
3Strength
If the drive gear is operated into a direction with engagement, then the gear is locked firmly, but no movement is possible and unlocking is difficult
Solution Approach 1:
The control device applies the inversion principle by operating the drive gear or lock gear in the opposite direction (reverse direction) when unlocking is required. This reverse operation counteracts the engagement forces that created the locked state, reduces tooth surface contact forces, and enables the lock gear to be pulled out successfully even when the gear was firmly locked during normal operation
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
Enables the gear train to be unlocked effectively even under load conditions by utilizing a control system that reverses polarity and direction, preventing gear contact and ensuring timely disengagement, thus maintaining operational efficiency.
Implementation Method 1
By attaching a solenoid to the lock gear, the drive gear is pulled into a locked state when the lock gear is simultaneously engaged with the both gears
Implementation Method 2
If the drive gear is driven by a main drive mechanism including a main motor and a main feedback circuit of a PI control system configured to generate, in response to an operation command, a current command from a sum of a proportional term and an integration term
Data Source
AI summary
For a gear train GL including a drive gear 33 and an idler gear 34 engaged with each other and a lock gear 35, provided are a first drive means 3A configured to linearly drive the lock gear 35 in forward and backward directions, a second drive means 3B configured to rotationally drive the drive gear 33 in normal and reverse directions, and a controller C configured to control the both drive means 3A and 3B. The controller C starts driving the lock gear 35 at the time of an unlocking operation, from an engagement position toward the disengagement position through the first drive means 3A, and when the drive is started, the controller C drives the drive gear 33 into one of normal and reverse directions and into the other direction through the second drive means 3B with a polarity reversal in a predetermined cycles T1 and T2.