Modular Reduction Gear With Safe Manual Clutch Decoupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mechanical power transmission systems for industrial valves and louvers are bulky and expensive to maintain, particularly when they need to operate in high-pressure fluid environments and require manual intervention, necessitating a compact and modular solution that allows for easy gear ratio changes and safe manual operation.
Innovation Solution
A mechanical power transmission system with a modular gearbox that includes a clutch mechanism with a driving part and a driven part, featuring a toothed ring and satellite pinions, allowing for inversion and interchange of components to modify the speed ratio between the rotary motor and the actuation mechanism, enabling easy gear ratio changes without adding new parts and ensuring safe manual operation by decoupling the motor from the actuation mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a mechanical power transmission system is designed to provide high torque for high-pressure fluid environments, then the torque capability is improved, but the device size and complexity increase
Solution Approach 1:
The power transmission system is divided into modular components: an electric motor module, a planetary gear reducer module, and a worm gear module. Each module can be independently selected and configured based on torque requirements, allowing high torque output without proportionally increasing overall system complexity. The modular design enables compact arrangement of high-torque components.
Solution Approach 2:
The planetary gear system is nested within the housing, with planet pinions rotating on carriers that are themselves nested within the reducer assembly. The worm gear is positioned at the output end of the planetary reducer, creating a compact nested arrangement that maximizes torque multiplication in a minimal space envelope.
2Adaptability or versatility
If manual operation capability is added to allow human intervention, then operational versatility is improved, but the risk of dangerous manual operation increases
Solution Approach 1:
A safety intermediary mechanism is introduced between the manual actuator and the power transmission system. This intermediary includes a disengagement mechanism that automatically disconnects the motor from the worm gear when manual operation is detected, preventing dangerous situations where both motor and manual forces could interact. The intermediary ensures only one mode of operation is active at a time.
Solution Approach 2:
The system dynamically switches between motor-driven and manual operation modes through a controllable disengagement mechanism. The connection between motor and load is made dynamic rather than fixed, allowing the system to adapt its coupling state based on operational requirements. This dynamic capability enables safe mode switching while maintaining both motor and manual operation options.
3Device complexity
If fixed gear ratio is used to simplify the design, then device complexity is reduced, but adaptability to different valve requirements decreases
Solution Approach 1:
The gear train is segmented into interchangeable modules with different gear ratios. The planetary gear set can be configured with different planet pinion arrangements, and the worm gear can be selected with various reduction ratios. This segmentation allows the system to be customized for different valve applications without redesigning the entire power transmission system.
Solution Approach 2:
The power transmission system is designed with universal mounting interfaces and standardized component connections that allow different gear ratio configurations to be installed in the same housing. The same basic structure can accommodate multiple gear ratio options, making the system universally adaptable to different valve torque and speed requirements without requiring completely different designs.
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 system provides a compact, cost-effective solution for high-torque applications, allowing for easy modification of gear ratios and safe manual operation, reducing maintenance costs and improving operational efficiency in high-pressure environments.
Implementation Method 1
a first planetary pinion (51a) and a second planetary pinion (51b) arranged coaxially and rotating in opposite directions about two different axes
Implementation Method 2
a worm screw (4) having two ends, a first end and a second end, the first end of the worm screw being coupled to the output gear (50)
Implementation Method 3
a rod disengaging mechanism exerting a thrust to disengage said motor from the first power input
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Mechanical power transmission system for controlling a valve or a louver, having a disengagement mechanism comprising a driving part (59) and a driven part together forming a dog clutch on an axis, the driven part having a toothed ring on a section axially opposite to its dog clutch driven part imprint, and being coupled to the actuation mechanism by said toothed ring and one or more stepped satellite gears meshing a toothed wheel of a sun pinion (50) of the power transmission system coupled to the first input by a central grooved bore, said sun pinion (50) having, on a section axially opposite to its toothed wheel, a driven part imprint complementary to the driving part (59), and said driven part having a central grooved bore complementary to said first input, the rod, for disengaging, passing through the two central bores and pushing a hub of the driving part (59).