Modular Bicycle Sprocket Mounting Unit Design
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Solution Overview
Problem
Conventional bicycle sprocket wheels and mounting units face manufacturing challenges due to complex structures and high costs, particularly for larger radius sprocket wheels, and often result in substandard quality and longer production times.
Innovation Solution
A modular mounting unit that connects multiple section units with fixing devices, allowing for easier and secure assembly of sprocket wheels without spacers, enabling replacement of individual units without discarding the entire wheel and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sprocket wheels are made by pressing, teeth formation, heat treatment, grinding, electro-coating and surface treatment, then the manufacturing process is standardized, but the manufacturing cost increases and production time lengthens for larger radius sprocket wheels with more teeth
Solution Approach 1:
The mounting unit is divided into multiple disks (first disk, second disk, third disk) that are connected together. Each disk can be manufactured separately using standardized pressing processes, then assembled into the complete mounting unit. This segmentation allows parallel manufacturing of components, reducing overall production time while maintaining quality standards for each individual component.
2Manufacturing precision
If sprocket wheels with larger radius and more teeth are manufactured using conventional methods, then the manufacturing precision standard is higher, but the manufacturing cost increases and requires more expensive methods such as forging or CNC machining
Solution Approach 1:
The mounting unit is divided into multiple disks (first disk, second disk, third disk) that can be manufactured separately using standardized pressing processes. This segmentation allows each component to be produced using cost-effective pressing technology rather than expensive forging or CNC machining, while the assembled structure achieves the required precision and performance for larger radius sprocket wheels.
Solution Approach 2:
The mounting unit design with multiple disks and multiple fixing portions can accommodate different sizes and configurations of sprocket wheels. The same basic mounting unit structure serves multiple functions and applications, reducing the need for specialized expensive manufacturing methods for each specific sprocket wheel size or configuration.
3Reliability
If multiple sprocket wheels are connected to the mounting unit using conventional mounting units, then the sprocket wheels are fixed securely, but spacers are required between the sprocket wheels increasing device complexity
Solution Approach 1:
The mounting unit integrates multiple fixing portions (first fixing portion, second fixing portion, third fixing portion, fourth fixing portion) distributed across multiple disks into a single unified structure. This merged design provides multiple fixation points for securing sprocket wheels directly to the mounting unit without requiring separate spacer components, thereby reducing device complexity while maintaining secure fixation.
4Ease of repair
If a modular mounting unit with multiple disks and fixing portions is used, then the assembly of sprocket wheels is simplified and individual section units can be replaced, but the device structure becomes more complex
Solution Approach 1:
The mounting unit is segmented into multiple disks (first disk, second disk, third disk) connected together, with each disk containing specific fixing portions. This segmentation enables modular assembly where individual disks or fixing portions can be replaced independently without discarding the entire mounting unit, facilitating easier repair and maintenance while the overall structure remains manageable.
Data Source
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AI summary
A mounting unit (40) for a bicycle sprocket wheel unit is made by way of pressing to form an integral ring plate which includes a hub connection hole (41) defined in the center thereof. A first disk (43), a second disk (44) and a third disk (45) are connected to the mounting unit and share the center of the hub connection hole. A first sprocket wheel (51) and a second sprocket wheel (52) are respectively located on two sides of the third disk. The second disk is connected to a third sprocket wheel (53) and a fourth sprocket wheel (54). The third disk is riveted to the first and second sprocket wheels along the whole face thereof to reinforce lateral strength of the sprocket wheels.