Gear Mechanism Thrust Washer Eccentric Shaft Connection
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Solution Overview
Problem
Existing transmission designs face challenges in achieving a compact, cost-effective, and stable configuration for high loads, particularly in securing rolling elements against axial and lateral forces while maintaining smooth operation.
Innovation Solution
The design incorporates a thrust washer with an off-center circular recess and a projection that securely connects to an eccentric shaft, allowing for a non-rotatable and play-free connection, combined with a two-row bearing arrangement and a double-sided planetary carrier for preload generation, enabling efficient torque transmission and stability against forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thrust washer with off-center recess and projection is used to connect to the eccentric shaft, then the connection stability and anti-rotation capability are improved, but the manufacturing complexity of the thrust washer increases
Solution Approach 1:
The thrust washer incorporates an off-center circular recess and a projection that creates an asymmetric geometry relative to the eccentric shaft. This asymmetric design ensures non-rotatable connection by matching the eccentric offset, preventing rotation while maintaining stable torque transmission. The asymmetric features directly address the connection stability requirement.
Solution Approach 2:
The thrust washer is pre-configured with the off-center recess and projection during manufacturing, enabling it to automatically align and lock onto the eccentric shaft without requiring additional alignment steps or adjustment mechanisms during assembly. This preliminary configuration simplifies the overall assembly process despite the complex geometry.
2Reliability
If a two-row bearing arrangement is used to secure rolling elements against axial and lateral forces, then the stability and load-bearing capacity are improved, but the device complexity increases
Solution Approach 1:
The patent combines two rows of bearings into a single integrated bearing unit that simultaneously handles both axial and lateral forces. This merged bearing arrangement provides comprehensive force support in multiple directions while occupying less space than separate bearing assemblies, addressing the stability requirement without proportionally increasing complexity.
Solution Approach 2:
The two-row bearing arrangement is designed to perform multiple functions simultaneously: supporting radial loads, accommodating axial forces, and maintaining rolling element positioning. This multi-functional bearing reduces the need for additional specialized components, balancing enhanced load-bearing capacity with controlled device complexity.
3Power
If the planetary carrier is designed as a double-sided structure with preloaded bearings, then the torque transmission efficiency and bearing stability are improved, but the manufacturing and assembly complexity increase
Solution Approach 1:
The double-sided planetary carrier incorporates preloaded bearings directly into its structure during manufacturing, establishing optimal bearing preload conditions before final assembly. This preliminary preload configuration ensures maximum torque transmission efficiency and bearing stability while eliminating the need for complex adjustment mechanisms during assembly.
Solution Approach 2:
The planetary carrier integrates multiple functions into a single double-sided structure: supporting multiple planet gears, providing bearing mounting surfaces, and generating preload forces through its geometric configuration. This merging of functions reduces the total number of separate components while achieving high torque transmission efficiency.
4Reliability
If the thrust washer projection covers the eccentric core area edge to prevent rotation, then the anti-rotation capability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The projection on the thrust washer is positioned asymmetrically to cover the edge of the eccentric core area, creating a mechanical interference fit that prevents rotation. This asymmetric positioning leverages the inherent eccentric geometry of the shaft, making the anti-rotation mechanism self-aligning and reducing sensitivity to manufacturing tolerances.
Solution Approach 2:
The design creates a stable equilibrium position where the projection naturally settles against the eccentric core area edge during assembly. This equipotential configuration ensures that minor manufacturing variations do not compromise the anti-rotation function, as the geometry itself provides the locking action.
Data Source
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AI summary
The invention relates to a thrust washer (50) for axially securing rolling elements of a bearing (15, 5), and a gear mechanism comprising said thrust washer (50), said thrust washer (50) being in the form of a circular disc (7) which has an axially protruding projection (51), particularly a radially outer projection, and said circular disc (7) comprising a recess arranged off-centre, wherein, in particular, the centre point of this preferably circular recess is thus positioned at a distance from the centre axis and/or from the centre point of the circular disc (7) and, in particular, the projection (51) is ring-shaped and the axis of the ring is positioned at a distance from the centre point of the preferably circular recess.