Distributed Necker Drive Assembly for Even Gear Load Distribution

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Solution Overview

Problem

Necker machines require a large number of processing and forming modules, leading to uneven gear wear and high costs due to oversized gears, as the rotational position of each module must be synchronized using a gear train driven at one end.

Innovation Solution

A distributed drive assembly with multiple drive sub-modules and extension shafts that interconnect drive shafts across modules, allowing the gear train to be driven at multiple locations, thereby distributing load more evenly and reducing the need for oversized gears.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a gear train is driven at one end to synchronize rotational positions of modules, then the modules can be synchronized, but the gear tooth load becomes very high at the driven end causing uneven gear wear and requiring oversized gears

Engineering Contradiction:

Improvesynchronization of module rotational positionsVSAvoidgear tooth load and wear distribution

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The single-end drive system is segmented into multiple drive units distributed along the gear train. Each drive unit independently drives a section of the gear train, dividing the total load into smaller segments. This segmentation reduces the gear tooth load at any single location while maintaining synchronization across all modules through coordinated control of the distributed drive units.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The drive system transitions from a one-dimensional single-point drive to a multi-dimensional distributed drive arrangement. Drive units are positioned at multiple locations along the length of the gear train, creating a spatial distribution of driving forces that evenly loads the gear teeth throughout the train rather than concentrating load at one end.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If oversized gears are used to handle high load at the driven end, then the gear train can withstand the load, but the cost increases due to unnecessary material and manufacturing expense

Engineering Contradiction:

Improvegear load capacityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Instead of uniformly oversized gears throughout the train, the distributed drive system enables local optimization where each gear's size and strength are matched to the actual local load requirements. Gears near the center of the train require less strength than those at the ends, allowing for cost-effective sizing that matches functional needs rather than worst-case scenarios.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The distributed drive configuration allows使用 smaller, less expensive gears throughout the train compared to a single-end drive system that would require oversized gears to handle the concentrated high load. The system trades the durability of a few large gears for many smaller, more cost-effective gears that collectively provide sufficient load capacity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If a large number of processing and forming modules are used in the necker machine, then the desired forming can be completed, but the gear train becomes longer and more complex

Engineering Contradiction:

Improveforming capabilityVSAvoidgear train complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The long gear train required for many modules is segmented into shorter sections, each driven by its own drive unit. This segmentation breaks the complexity of a single long drive train into multiple manageable sections, reducing the complexity of each individual gear train segment while maintaining the overall productivity through coordinated operation of all segments.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20220364639A1Drive assembly

Publication Date: 2022.11.17 STOLLE MACHINERY CO LLC

AI summary

A distributed drive assembly for a necker machine having a frame assembly and a plurality of modules, each module having a number of drive shafts, the number of drive shafts of each module interconnected via a gear train with the number of drive shafts of the other modules of the plurality of processing modules. The distributed drive assembly includes: a plurality of drive sub-modules, each drive sub-module having: an input shaft; a first output shaft operatively coupled to the input shaft; and a second output shaft operatively coupled to the input shaft. For a first drive sub-module: the input shaft is structured to be operatively coupled to, and driven by, a main drive assembly motor, and the first output shaft is structured to be operatively coupled to, and drive, an associated first drive shaft of the number of drive shafts of a first module of the plurality of modules. For a second drive sub-module: the input shaft is operatively coupled to, and driven by, the second output shaft of the first drive sub-module, and the first output shaft is structured to be operatively coupled to, and drive, an associated first drive shaft of the number of drive shafts of a second module of the plurality of modules that is separated from the first module by at least one other module.