Non-Circular Gearing Part Torque Transmission
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Solution Overview
Problem
Existing toothed parts are not produced cost-effectively, as they require complex connections that are time-consuming and expensive to manufacture, especially when aiming for high torque transmission and reliability.
Innovation Solution
A toothed part design featuring a wheel body with a non-circular section that corresponds to a similarly shaped wheel rim, allowing for efficient torque transmission through a non-round profile, with stepped or conical sections for reduced joining length and easy assembly, using materials like bronze for the rim and steel for the body to minimize costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional round connection design is used between wheel rim and wheel body, then the manufacturing process is simple, but the torque transmission capability is insufficient and the connection length is large
Solution Approach 1:
The patent applies asymmetry by replacing the conventional round connection design with a non-circular connection profile. The wheel body features a non-circular section with varying radial distance as a function of angle, while the wheel rim has a correspondingly shaped section. This asymmetric geometry creates form-fitting connection surfaces that significantly enhance torque transmission capability through mechanical interlocking, while the specific profile design allows for reduced connection length compared to conventional round designs.
2Power
If a non-circular profile with complex geometry is used to enhance torque transmission, then the torque capability improves, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent applies parameter changes by defining the non-circular profile through mathematical functions where the radial distance varies as a function of the angle. This parametric approach allows for optimized torque transmission while maintaining manufacturability, as the complex geometry is generated through controlled variation of geometric parameters rather than freeform design. The connection surfaces are created with specific functional relationships that balance performance requirements with manufacturing capabilities.
3Loss of substance
If the wheel rim is made thin-walled to reduce material cost, then material costs decrease, but the connection reliability and torque transmission may be compromised
Solution Approach 1:
The patent applies composite materials by combining different materials for the wheel rim and wheel body. The wheel rim can be made from materials optimized for its specific function (such as aluminum alloys or other lightweight materials), while the wheel body is made from a different material (such as steel or cast iron) that provides structural support and connection stability. This material differentiation allows the thin-walled rim to maintain connection reliability through the form-fitting non-circular interface and composite construction, while reducing overall material costs by using appropriate materials in each component.
Data Source
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AI summary
Gearing part and method for producing a gearing part comprising a gearing body surrounded by a wheel rim, the gearing body comprising in a first axial area a section designed as non-circular, to which a correspondingly formed section of the wheel rim is connected.