Integral Spring Split Gear Backlash Reduction
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Solution Overview
Problem
Conventional split gears for reducing backlash in gear systems are complex to assemble, require multiple components, and introduce unwanted friction and tolerance stack-ups, leading to reliability issues and increased energy dissipation.
Innovation Solution
A split gear design where the spring is integrally formed with the second gear wheel, allowing for independent adjustment of resiliency and reducing the number of assembly components, with options for torsion or annular springs and bayonet mounts for simplified assembly and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional split gear with separate spring element and multiple components is used, then backlash can be reduced, but device complexity increases and reliability decreases
Solution Approach 1:
The spring element is integrally formed with the second gear wheel as a single piece, eliminating the need for separate spring components and fastening means. This merging of the spring and gear wheel reduces the number of parts, simplifies assembly, and improves reliability by eliminating interfaces between separate components.
2Reliability
If multiple separate components are assembled to form the split gear, then backlash reduction is achieved, but manufacturing precision decreases due to tolerance stack-up
Solution Approach 1:
The integral formation of the spring element with the second gear wheel eliminates multiple assembly interfaces and fastening connections. This reduces tolerance stack-up between separate components, improving manufacturing precision and ensuring more consistent performance.
3Strength
If separate fastening means are used to attach the spring to the gear wheel, then the spring can be secured, but friction and energy dissipation increase
Solution Approach 1:
The integral design eliminates fastening means such as screws or clips that create friction interfaces. The spring element and gear wheel form a continuous structure with no separate connection points, reducing friction and energy dissipation while maintaining structural strength.
4Reliability
If multiple components are used in the split gear assembly, then backlash can be controlled, but ease of manufacture decreases
Solution Approach 1:
The spring element and second gear wheel are formed as a single integral component, reducing the number of parts that need to be manufactured, stored, and assembled. This simplifies the manufacturing process, reduces assembly steps, and improves ease of manufacture while maintaining the backlash control function.
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
This design simplifies assembly, reduces friction and tolerance stack-ups, enhances reliability, and allows for compact and homogeneous mass distribution, effectively absorbing opposing torques and minimizing backlash.
Implementation Method 1
The first and the second gear wheel are resiliently interconnected by a spring element... The spring creates a negative moment between the first and the second gear wheel when the first and the second gear wheel are rotated relatively with respect to each other
Implementation Method 2
the spring is a torsion spring... Upon rotation of the second gear with respect to the first gear, the annular spring deforms causing the creation of the negative moment. The negative moment causes that the engaging teeth of the mating gear are clamped between the engaging teeth of the first and second gear
Data Source
AI summary
Split gear (1) for avoiding backlash when engaging a mating gear (4), comprising a first (2) and second (3) toothed gear wheel, rotating means (5) for coaxially interconnecting the first (2) and second (3) gear at least partially rotatable with respect to each other around a mutual rotational axis (15) and a spring (10) resiliency interconnecting the first (2) and second (3) gear for creating a negative moment between the first (2) and second (3) gear upon alignment of the teeth (12, 13) of the first (2) and second (3) gear by rotation of the first (2) gear with respect to the second (3) gear so that the mating gear (4) can be engaged, characterized in that the spring (10) is integrally formed with the second (3) gear wheel.