Modular Gear System Assembly With Standardized Torque Interfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing transmission systems are time-consuming and costly due to the need for individual customization to match varying drive devices and systems to be driven, often requiring complex and costly adaptations to accommodate different designs, sizes, and torque requirements.
Innovation Solution
A method that allows for the efficient and cost-effective production of transmission systems by using standardized components, including torque support elements and attachment elements, which can be combined in various configurations to match specific application conditions, enabling quick adaptation to different drive devices and systems, with a focus on simple and reliable torque transmission through non-positive connections and modular assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If customized transmission systems are manufactured for each drive device and driven system combination, then adaptability to different designs and specifications is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The transmission system is divided into modular components: coupling device, transmission unit, and driven system connection elements. Each module can be independently manufactured and then assembled through standardized interfaces, enabling customization without full redesign of each complete system.
Solution Approach 2:
Standardized torque support elements and attachment elements are designed with universal interfaces that can accommodate multiple drive device types and configurations. These standardized components serve multiple functions across different applications, reducing the need for custom-manufactured parts while maintaining adaptability.
2Adaptability or versatility
If complex adaptations are made to accommodate different drive device designs, sizes, and torque requirements, then versatility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The torque support element is designed as a universal component with standardized attachment elements that can interface with various drive device configurations. This single standardized design accommodates different designs, sizes, and torque requirements without requiring complex custom adaptations for each application.
Solution Approach 2:
The system accommodates different torque requirements and drive device specifications by selecting from predefined standardized components with varying parameters (sizes, torque ratings, mounting configurations) rather than designing custom solutions, thereby reducing overall system complexity.
3Manufacturing precision
If individual customization is performed for each transmission system, then precision of fit and performance optimization are improved, but manufacturing time and productivity decrease
Solution Approach 1:
The system separates precision-fit requirements into standardized interface definitions at the module level. Once interfaces are precisely defined for each module type, assembly becomes a straightforward connection process that maintains precision without requiring time-consuming custom fabrication for each complete system.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for manufacturing a transmission system (1). The method includes the step of providing a plurality of different transmission units (2), each of which has a torque support element (3) that is identical for all transmission units for fixing to a coupling device (4). The method also includes the step of providing a plurality of coupling devices (4), each of which has a coupling device housing (7) and each of which is designed for torque-transmitting coupling of a torque-supplying drive device (5) to a transmission unit (2), and each of which has an attachment element 6 that is identical for all transmission units (2) and is designed as a counterpart to the identical torque support elements (3) such that each transmission unit (2) of the plurality of transmission units (2) can be mounted to each of the coupling devices (4).The method also includes the steps of selecting a gear unit (2) from the plurality of gear units (2) and selecting a coupling device (4) from the plurality of coupling devices 4. The method also includes the steps of providing a plurality of different transmission shafts, selecting a transmission shaft and mounting the selected transmission shaft into a transmission shaft receptacle of the selected coupling device.The procedure also includes the step of mounting the selected gear unit (2) to the selected coupling device (4) by establishing a torque-transmitting connection of an output end (10) of a transmission shaft (8) with a gear input (9) of the selected gear unit (2) and by establishing a torque-supporting connection between the coupling device housing (7) and the torque support element 3 of the selected gear unit (2).