Interlocking Sprocket Segments with Dovetail Load Distribution

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Sprockets used in heavy earth-moving and construction equipment face rapid wear due to lateral and vertical forces, leading to frequent replacements and increased maintenance costs, as existing designs do not effectively distribute loads across multiple segments.

Innovation Solution

A sprocket assembly with interlocking segments featuring dovetail recesses and projections, which share radial and circumferential loads between segments, reducing the load on individual fasteners and extending the lifespan of the sprocket assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If sprocket segments are used to reduce wear on individual lugs, then the sprocket assembly can be maintained more economically, but the fasteners on each segment wear quicker due to concentrated load

Engineering Contradiction:

Improvesprocket maintenance costVSAvoidfastener wear resistance

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

The sprocket is divided into multiple segments that can be independently replaced. Each segment contains lugs that engage with the track chain, allowing only the worn segment to be replaced rather than the entire sprocket assembly, thereby reducing maintenance costs and improving ease of repair.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple sprocket segments are combined to form a complete sprocket assembly. The segments are arranged circumferentially and work together to distribute the load from the track chain across multiple lugs and fasteners, preventing excessive wear on any single fastener while maintaining the benefits of modular replacement.

Inventive Principle:

Principle #5Merging (Combining)

2Loss of time

If fewer fasteners are used per segment for easier replacement, then maintenance time is reduced, but the load on each fastener increases causing quicker wear

Engineering Contradiction:

Improvemaintenance timeVSAvoidfastener load capacity

Core Design Contradiction:

Loss of timeVSStrength

Solution Approach 1:

The sprocket assembly is segmented into replaceable units, each with a specific number of fasteners optimized for its function. This segmentation allows for quick replacement of worn segments without requiring disassembly of the entire sprocket, reducing maintenance time while maintaining adequate fastener load capacity through proper segment design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each sprocket segment is designed with a specific configuration of fasteners and lugs tailored to its local function. The fastener distribution and lug geometry are optimized for each segment to ensure adequate load capacity while minimizing the total number of fasteners required, balancing maintenance speed with structural strength.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11794830B2Sprocket locking segments

Publication Date: 2023.10.24 CATERPILLAR INC

AI summary

A sprocket segment includes a body with an attachment web including a first circumferential end and a second circumferential end. A sprocket region extends radially outwardly from the attachment web, including a plurality of lugs. The first circumferential end includes a dovetail recess including a first side flat surface extending circumferentially and radially from the first circumferential end, a second side flat surface extending circumferentially and radially from the first circumferential end, and an arcuate bottom surface extending radially between the first side flat surface and the second side flat surface.