Motorized Worm and Planetary Gear Coupling for Remote Damper Control
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Solution Overview
Problem
Existing gear systems require separate couplings and attachments for shafts to worm and planetary gears, which can be cumbersome and inefficient, especially when trying to accommodate shafts of different sizes and shapes, and lack a unified motorized control system for remote operation.
Innovation Solution
A gear and coupling system that integrates a worm coupling with the worm gear's axle, allowing for secure attachment of shafts through set screws, and includes a motor and controller for electromechanical operation, enabling remote control of rotational motion across different axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate couplings and attachments are used for shafts to worm and planetary gears, then the system can accommodate different shaft configurations, but the device complexity and ease of operation deteriorate due to cumbersome assembly
Solution Approach 1:
The patent combines the coupling and attachment functions into a single integrated coupling device that includes a body with a bore and set screw holes. This merging eliminates the need for separate coupling and attachment components, reducing device complexity while maintaining the ability to accommodate different shaft configurations through the bore and set screw mechanism.
Solution Approach 2:
The coupling device is designed with universal functionality to accommodate shafts of different sizes and shapes. The bore can receive various shaft diameters, and the set screws can be adjusted to secure different shaft configurations, making the same coupling device applicable to multiple shaft types without requiring specialized components for each shaft size.
2Reliability
If separate couplings and attachments are used for shafts, then the system can be assembled, but the ease of operation worsens due to cumbersome assembly and adjustment
Solution Approach 1:
The coupling and attachment functions are merged into a single integrated device, eliminating the need for separate assembly steps for coupling and securing the shaft. The set screws are built into the coupling body, allowing the user to attach the shaft in one operation rather than requiring separate coupling and attachment procedures.
Solution Approach 2:
The coupling device incorporates set screws that can be directly adjusted and tightened by the user without requiring additional tools or separate attachment mechanisms. The self-contained design with integrated set screws allows the coupling to service its own attachment function, simplifying the operation and reducing the need for external assembly procedures.
3Ease of operation
If manual rotation of shafts is used, then the system can operate, but the productivity and power deteriorate compared to motorized operation
Solution Approach 1:
The patent introduces a motor as an intermediary device that converts electrical energy to mechanical rotation, mediating between the power source and the gear system. The motor drives the worm shaft, which then transfers rotational movement through the worm gear and planetary gear to the output shaft, enabling motorized operation that significantly increases productivity and power compared to manual rotation.
Solution Approach 2:
The patent replaces the manual mechanical input system with an electromechanical system. Instead of requiring direct manual rotation of the worm shaft, an electric motor provides the rotational force, substituting human physical effort with electromagnetic actuation. This substitution dramatically increases the power and speed capabilities of the system while maintaining the mechanical gear transmission mechanism.
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 system simplifies the attachment and control of shafts across different axes, accommodating various shaft sizes and shapes, and allows for efficient remote operation of mechanisms like dampers in HVAC systems, enhancing flexibility and ease of use.
Implementation Method 1
The motor may be direct current, low voltage, low torque, and low rpm. The controller regulates the motor, particularly by activating and deactivating the motor as well as controlling the direction and distance the motor rotates the worm shaft.
Implementation Method 2
Worm and planetary gears work together to transfer rotational movement in one plane to another plane. The worm gear and planetary gear (also commonly referred to as a worm and worm gear, respectively) are placed in rotational engagement with each other so that the threads of the worm gear mesh with the teeth of the planetary gear.
Implementation Method 3
Both couplings include bores through which set screws are inserted so that they engage the shafts. Thus, the shafts are held in place. Shafts of different sizes and shapes may be accommodated by the distance by which the set screws are inserted into the couplings.
Data Source
AI summary
A system for controlling airflow in a plenum, that comprises a worm gear and planetary gear that are removably coupled to a worm shaft and planetary shaft, respectively. The planetary shaft controls the movement of a damper between an open position permitting maximum airflow through the plenum, and a closed position restricting airflow through the plenum. A motor or gear-motor is positioned at the plenum for driving the worm shaft. The motor is controlled by a remotely located controller that includes a power supply for operating the motor and that has a display providing a continuous indication of the position of the damper between the open and closed positions. The controller is connected to the motor through a cable with a detachable electrical connection between the cable and the controller, such as a jack and plug. A wall plate for housing the electrical connection is mounted on a wall or other structure. The wall plate has a first plate for housing the jack and a second plate with a flexible flange for removably securing the jack in the housing by snap fit insertion.