Multi-Disc Sprocket Assembly for Precise Wide Tooth Profiles
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Solution Overview
Problem
Existing manufacturing methods for larger width sprockets face challenges in forming precise tooth profiles without creating drafting angles, leading to inefficiencies and increased costs, especially in die casting and sand casting processes.
Innovation Solution
A multi-disc sprocket design comprising coaxially aligned disc sprockets with identical outer diameters and tooth profiles, secured by flanges and fasteners, allowing for efficient assembly and alignment, and potentially using stamped disc sprockets to reduce production costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die cast method is used to manufacture sprockets, then manufacturing cost is reduced and tooth profile precision is improved, but sprocket width is limited due to drafting angle requirements
Solution Approach 1:
The sprocket is divided into multiple thin disc-shaped components stacked coaxially together. Each individual disc can be die cast with precise tooth profiles without drafting angles, and when stacked, they form a wide sprocket assembly that overcomes the width limitation of single-piece die casting.
2Length of moving object
If sand casting technique is used for larger width sprockets, then sprocket width is increased, but manufacturing cost increases and tooth profile precision decreases
Solution Approach 1:
Instead of casting a single large-width sprocket that requires expensive machining, multiple thin discs are die cast with precise tooth profiles and stacked together. This segmentation allows each component to be manufactured with high precision using economical die casting, then assembled to achieve the desired total width.
Solution Approach 2:
Multiple individual disc sprockets are combined coaxially through flanges and fasteners to create a multi-disc sprocket assembly. The merging of these precision-cast discs produces a wide sprocket that maintains high tooth profile precision while achieving the required width.
3Length of moving object
If sand casting with machining techniques is used, then sprocket width is increased, but manufacturing time and cost increase
Solution Approach 1:
The sprocket is segmented into multiple thin discs that can be die cast simultaneously or in parallel. This eliminates the need for time-consuming machining operations on single large-width sprockets, significantly improving manufacturing efficiency while achieving the required width.
Solution Approach 2:
The invention uses multiple inexpensive thin disc components that can be rapidly die cast and assembled, replacing the expensive and time-consuming process of machining large-width sprockets. The individual discs are simple, economical components that achieve the overall width requirement through assembly.
Data Source
AI summary
A sprocket system including a sprocket assembled from multiple disc sprockets coaxially aligned and secured together to provide a desired axial width for the sprocket is described. In some embodiments, the sprocket described herein is a hub-less sprocket.