Lubricating Pinion Module Segmented Channels
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Solution Overview
Problem
Existing lubricating pinion modules face issues with inconsistent lubricant distribution due to temperature changes, inefficient sealing, and high friction at high speeds, leading to lubricant leakage and degradation.
Innovation Solution
A lubricating pinion module with a toothed element and a bearing element connected in a rotationally fixed manner using a form-fitting connection, eliminating the need for additional sealing elements and allowing for continuous lubricant channels to be formed during manufacturing, ensuring reliable lubricant delivery over a wide temperature range and high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lubricant is present in the entire toothed area made of foam, then lubricant is always available for lubrication, but lubricant is also provided at points that do not require lubrication and the system becomes less efficient
Solution Approach 1:
The toothed element is segmented into multiple lubricant channels that are distributed throughout the structure. Each channel independently supplies lubricant to specific contact points, preventing unnecessary lubricant presence in non-contact areas while ensuring reliable supply at required locations.
Solution Approach 2:
Lubricant is delivered locally to specific contact points through dedicated channels rather than being uniformly distributed throughout the entire toothed element. This ensures lubricant is present only where needed for actual gear contact, improving efficiency while maintaining reliability.
2Quantity of substance
If foam structure is used for toothed element, then lubricant storage capacity is increased, but at sub-zero temperatures the lubricant becomes stiff and cannot be removed from foam, causing the sprocket to harden
Solution Approach 1:
The lubricant storage is segmented into multiple distributed channels within the toothed element rather than a single foam reservoir. This channelled structure allows controlled lubricant flow even at low temperatures, preventing the hardening issue while maintaining storage capacity.
Solution Approach 2:
The lubricant delivery mechanism is designed to accommodate temperature-induced viscosity changes. The channelled structure allows lubricant to be delivered under pressure to contact points regardless of its viscosity state, ensuring operational reliability across the temperature range while maintaining storage capacity.
3Quantity of substance
If foam structure is used for toothed element, then lubricant storage is improved, but at plus degrees the lubricant becomes too thin and too much lubricant is provided on the elements to be lubricated
Solution Approach 1:
The toothed element is divided into multiple lubricant channels that independently control lubricant delivery to specific contact points. This segmentation prevents excessive lubricant application by delivering lubricant only where and when needed, even when the lubricant has low viscosity at elevated temperatures.
Solution Approach 2:
Lubricant delivery is localized to specific contact points through dedicated channels rather than allowing uncontrolled distribution throughout the foam structure. This ensures precise lubricant application even when the lubricant becomes thin at higher temperatures, preventing over-application and waste.
4Ease of manufacture
If two-part design with lubricant channels is used, then production of lubricant channels is simplified, but sealing between parts becomes very complex requiring support sleeves, screws and washers
Solution Approach 1:
The lubricant channels are integrated directly into the toothed element structure rather than being separate components requiring assembly and sealing. This merging of the channel structure with the main body eliminates the need for complex sealing arrangements while maintaining ease of channel production.
Solution Approach 2:
The toothed element structure serves multiple functions: it provides the gear teeth for meshing and simultaneously contains the lubricant channels as an integrated feature. This multi-functionality eliminates the need for separate sealing components, reducing device complexity while maintaining manufacturing ease.
5Speed
If lubricating pinion module rotates at high speed, then lubrication coverage is improved, but friction on the shaft and element to be lubricated increases causing large temperature rise and lubricant degradation
Solution Approach 1:
The lubricant supply is segmented into multiple channels that deliver lubricant directly to various contact points on the gear teeth. This ensures adequate lubrication at high speeds without requiring excessive friction, reducing heat generation and preventing lubricant degradation.
Solution Approach 2:
Lubricant is delivered locally to each contact point through dedicated channels, ensuring optimal lubrication at high rotation speeds. This localized delivery reduces overall friction and heat generation by ensuring proper lubrication where contact occurs, preventing temperature rise and lubricant degradation.
Data Source
Figure 1
Figure 2
AI summary
A lubrication pinion module (1), particularly for a lubrication device, for applying a lubricant to an element to be lubricated, in particular a gear, is disclosed, wherein the lubrication pinion module (1) comprises a toothed element (2) and a bearing element (4), wherein the toothed element (2) is designed to supply the element to be lubricated with lubricant and the bearing element (4) is designed to support the lubrication pinion module (1) on a shaft, wherein the bearing element (4) and the toothed element (2) are rotationally fixed to one another, wherein the bearing element (4) has at least one, preferably several, recesses (6; 8; 10) designed to provide a positive locking connection with the toothed element (2), and wherein the at least one recess (6; 8; 10) of the bearing element (4) is positively filled with the material used for manufacturing the toothed element (2).