Multipart Sprocket Segmented Design for Cost and Torque
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Solution Overview
Problem
Existing sprocket designs for torque transmission in gear systems, particularly in motorcycles, face high construction and manufacturing costs due to the need for 3-D manufacturing techniques and are not suitable for high-torque transmission under unfavorable conditions like motocross rides.
Innovation Solution
A multipart sprocket design featuring a 2-D manufactured inner ring and gear rim with form-fitting lugs and conical depressions, allowing for axial and radial connection, and the use of different materials and thicknesses, enabling cost-effective production and high-strength, robust, and aesthetically versatile components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If 3-D manufacturing techniques are used to create pocket-like recesses in the inner ring, then the sprocket can achieve proper gear engagement, but the manufacturing costs increase significantly
Solution Approach 1:
The patent transforms the 3-D pocket-like recesses into 2-D radial openings that extend from the inner circumference to the outer circumference of the inner ring. This dimensional simplification allows standard 2-D manufacturing techniques to be used instead of complex 3-D manufacturing, significantly reducing production costs while maintaining proper gear engagement through the form-fitting lugs
2Ease of manufacture
If the inner ring and gear rim are joined with simple fastening methods, then the manufacturing cost is reduced, but the torque transmission capability under unfavorable conditions deteriorates
Solution Approach 1:
The sprocket is divided into two separable components: the inner ring and the gear rim. This segmentation allows each component to be manufactured independently using simple 2-D techniques, reducing manufacturing costs. The components are then joined through form-fitting lugs that provide robust torque transmission capability under unfavorable conditions while maintaining ease of manufacture
Solution Approach 2:
The inner ring features localized form-fitting lugs with radial openings that provide enhanced torque transmission capability at critical engagement points. This local reinforcement strategy maintains overall manufacturing simplicity while strengthening the connection between components where it is most needed for high-torque applications
3Strength
If the gear rim is designed as a single integrated piece, then the structural strength is improved, but the ease of replacing worn components is reduced
Solution Approach 1:
The sprocket is segmented into the inner ring and the gear rim as separate components. The gear rim can be removed and replaced independently when worn, while the inner ring remains intact. This segmentation maintains structural strength through the form-fitting lug design while significantly improving component exchangeability for maintenance and repair operations
4Weight of moving object
If the inner ring is designed with reduced material thickness, then the weight is reduced, but the strength and robustness deteriorate
Solution Approach 1:
The inner ring employs form-fitting lugs with radial openings that concentrate material strategically at the engagement points where torque transmission occurs. This localized material distribution reduces overall weight while maintaining strength and robustness at the critical load-bearing regions, achieving an optimal balance between weight reduction and structural integrity
Data Source
AI summary
The invention relates to a multipart sprocket (1), in which an inner ring (2) for fixing the multipart sprocket (1) to a wheel hub comprises through-holes (5) which are located on a common hole circle, wherein the inner ring (2) on the periphery thereof comprises radially outwardly directed inner ring lugs (2A) for receiving a gear rim (8), and the gear rim (8) comprises radially inwardly directed gear rim lugs (11) which are spatially associated with the radially outwardly directed inner ring lugs (2A), and means (12, 13, 14) are present, which connect the inner ring (2) and the gear rim (8) axially and radially.