Keyless Timing Gear Assembly for Precise Pump Gear Synchronization
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Solution Overview
Problem
Accurate synchronization of bull gears on a crankshaft in reciprocating pumps is challenging due to manufacturing tolerances, requiring costly manual corrections and precise key-based connections, which can lead to mechanical stress and inefficiencies.
Innovation Solution
A keyless timing gear assembly that uses actuators, expansion members, and wedge members to securely fasten bull gears to the crankshaft, eliminating the need for manual adjustments and keys by creating a friction joint through compressive stresses, ensuring synchronized rotation and even power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If key-based connections are used to secure bull gears to the crankshaft, then precise synchronization can be achieved, but mechanical stress increases and device complexity increases
Solution Approach 1:
The patent replaces the traditional key-based mechanical connection system with a friction-based pressure fit system. The bull gear is secured to the crankshaft through radial compressive forces created by actuators that push wedge members against the gear, eliminating keys and keyways. This substitution reduces stress concentration points while maintaining synchronization precision through even force distribution around the gear perimeter.
Solution Approach 2:
The patent employs hydraulic actuators to generate the radial compressive forces needed to secure the bull gear to the crankshaft. These actuators convert hydraulic pressure into mechanical force, pushing wedge members that create friction-based locking. This pneumatic/hydraulic approach provides smooth, adjustable force application without the mechanical stress concentrations inherent in key-based systems.
2Measurement precision
If manual corrections are performed to account for manufacturing tolerances, then synchronization accuracy improves, but time consumption increases and productivity decreases
Solution Approach 1:
The patent transforms the synchronization problem from a precision positioning challenge to a force distribution problem. By using radial compressive forces that can be uniformly applied around the bull gear perimeter, the system automatically compensates for manufacturing tolerances in gear and crankshaft dimensions. The hydraulic actuators can adjust force parameters to accommodate variations without requiring manual measurement and correction procedures.
Solution Approach 2:
The friction-based pressure fit system is self-aligning and self-adjusting. The radial compressive forces automatically distribute around the bull gear, creating even contact pressure that compensates for manufacturing variations. The system self-regulates through the friction interface between the gear and crankshaft, eliminating the need for operator intervention to correct synchronization issues.
3Device complexity
If traditional key-based fastening is used, then structural simplicity is maintained, but device complexity increases due to additional alignment components
Solution Approach 1:
The patent replaces the key-based mechanical fastening system with a friction-based pressure fit system. Instead of using keys, keyways, and alignment components, the system uses radial compressive forces generated by hydraulic actuators pushing wedge members. This substitution simplifies the fastening mechanism by eliminating multiple discrete alignment components while improving ease of operation through automated force application and distribution.
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
The keyless timing gear assembly simplifies the synchronization process, reduces mechanical stress, and maintains even power input to the crankshaft, enhancing operational efficiency and reducing the need for precise manual corrections.
Implementation Method 1
a wedge member (156) disposed between the at least one actuator and the expansion member, the wedge member having a surface to slideably engage a corresponding surface on the expansion member
Implementation Method 2
an expansion member (152) disposed between the bull gear and the crankshaft... the expansion member radially expanding to create a friction joint between the bull gear and the crankshaft
Implementation Method 3
the at least one wedge member exerts a force on the expansion member for securing the first bull gear to the crankshaft
Data Source
AI summary
A keyless timing gear assembly for securing a bull gear to a crankshaft of a power end of a reciprocating pump assembly, the keyless timing gear assembly including at least one actuator, an expansion member and at least one wedge member disposed between the at least one actuator and the expansion member, the wedge member having a sloped surface to slideably engage a corresponding sloped surface on the expansion member such that, in response to actuation of the at least one actuator, the at least one wedge member exerts a force on the expansion member for securing a bull gear to a crankshaft.