Double-Shaft Mixer Drive Device Gear Train Synchronization
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Solution Overview
Problem
Existing drive devices for twin-shaft mixers face issues with synchronization reliability, space efficiency, and cost due to the use of V-belts and toothed belts, which wear out and fail to maintain synchronization under sudden loads, and occupy excessive space with motor and gear arrangements.
Innovation Solution
The drive device employs a gear train with spur gears, bevel gears, or worm gear drives to transmit torque directly, eliminating belt-driven transmissions and using a bevel gear arrangement to non-parallelly align motor, synchronization, and output shafts, allowing for compact motor placement and synchronization via cardan joints and couplings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If V-belts or toothed belts are used to drive the mixer shafts, then the motors can be positioned separately from the gears, but the belts wear out over time and fail to maintain synchronization under sudden loads
Solution Approach 1:
The patent removes the belt transmission element from the drive system entirely, replacing it with a direct gear train connection. This extraction of the problematic belt component eliminates wear and slippage issues while maintaining motor positioning flexibility through the gear train design.
Solution Approach 2:
The patent substitutes the belt-driven mechanical system with a gear-driven mechanical system. The gear train provides positive engagement through toothed contact, replacing the friction-based belt transmission and ensuring reliable torque transfer without slippage or wear.
2Ease of manufacture
If V-belts or toothed belts are used for transmission, then installation is simplified, but the belts are subjected to high jerky forces that cause teeth to jump or belts to tear
Solution Approach 1:
The patent replaces the belt transmission system with a gear train system that uses direct toothed engagement. This substitution eliminates the tensile stress concentration that occurs in belts under sudden loads, as gears transfer force through compressive contact between teeth, significantly increasing load-bearing capacity.
3Device complexity
If motors and gears are arranged next to one another on one end face of the mixer, then the drive train is compact, but the arrangement occupies a relatively large amount of space
Solution Approach 1:
The patent utilizes the vertical dimension by positioning the motor above or below the gearbox rather than arranging components horizontally on the same end face. This vertical stacking arrangement reduces the horizontal footprint while maintaining a compact drive train configuration.
Solution Approach 2:
The patent employs a nested arrangement where the motor is positioned directly above or below the gearbox, with the drive shaft passing through the gearbox vertically. This nesting of components in the vertical direction minimizes the overall space occupation while maintaining functional connectivity.
4Reliability
If a worm shaft is used for synchronization, then synchronization is achieved, but belt tension must be adjusted and exact alignment is necessary which causes additional load on the transmission
Solution Approach 1:
The patent removes the belt tensioning mechanism and worm shaft synchronization system entirely, replacing them with a direct gear train connection between motors and a cardan joint coupling between synchronization shafts. This extraction eliminates the need for belt tension adjustment and precise alignment procedures.
Solution Approach 2:
The patent changes the synchronization mechanism from belt-based tension-dependent synchronization to gear-based positive engagement synchronization. This parameter change in the synchronization method eliminates sensitivity to tension variations and alignment precision requirements.
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 solution ensures reliable synchronization, reduces space usage, and lowers production costs by eliminating belt wear and slippage, while maintaining synchronization even under high torque loads and ensuring efficient torque transfer.
Implementation Method 1
the transmission of torque from the engine output shaft to the transmission output shaft, which is directly connected to the mixer shaft, is effected exclusively via shafts that mesh with toothings
Implementation Method 2
synchronization via cardan joints and couplings
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a drive device for double-shaft mixers (2) comprising a drive motor (3) and a gearbox having a bevel gear drive, wherein the gearbox components engage one another exclusively via gear teeth, and to a corresponding double-shaft mixer. The drive motor (3) is located above the gearbox and the axis of rotation thereof is vertical.