Passive Geared Shaft Assembly With Low-Force Press-Fit Teeth
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Solution Overview
Problem
The existing splined shaft systems face difficulties in assembly, particularly when using automated force-displacement-controlled methods, due to high joining forces required for sensor wheels and low search forces needed for cam pieces, which can lead to damage and increased production costs, especially with the use of additional connecting elements and axial bearings.
Innovation Solution
The splined shaft system incorporates an external toothing with first and second toothing gaps and a functional element with press-toothed teeth, allowing for a fitting toothing with play initially and a backlash-free fitting toothing subsequently, using a toothing-free section to facilitate easy assembly without additional connecting elements or axial bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional connecting elements and axial bearings are used to secure the functional element, then the reliability of the connection is improved, but the device complexity and manufacturing effort increase significantly
Solution Approach 1:
The patent combines the functional element directly with the toothed shaft by integrating the toothing structures, eliminating the need for separate connecting elements and axial bearings. The functional element's internal toothing engages with the toothed shaft's external toothing to form a unified assembly, reducing part count and assembly complexity while maintaining connection reliability.
Solution Approach 2:
The patent removes unnecessary components (connecting elements and axial bearings) from the assembly by designing a direct toothing engagement system. The extraction of these auxiliary components simplifies the overall structure while the toothing design provides sufficient mechanical engagement and positioning functions.
2Strength
If high joining forces are applied to push the functional element onto the toothed shaft, then the connection strength is improved, but the risk of tooth damage increases and automated assembly becomes difficult
Solution Approach 1:
The toothing is divided into two distinct sections: a first toothing section with larger pitch circle diameter for initial engagement with lower forces, and a second toothing section with smaller pitch circle diameter for final secure engagement. This segmentation allows the assembly process to progress from low-force alignment to high-strength connection without damaging the teeth.
Solution Approach 2:
The first toothing section performs the preliminary action of guiding and aligning the functional element with the toothed shaft during initial engagement. This preliminary alignment reduces misalignment forces and prepares the assembly for the subsequent high-strength engagement in the second toothing section, enabling automated force-displacement-controlled assembly.
3Ease of operation
If the toothing sections are designed with different diameters to facilitate assembly, then the ease of assembly is improved, but the structural complexity of the toothed shaft increases
Solution Approach 1:
The toothed shaft's toothing structure serves multiple functions through its two sections: the first section provides guidance and alignment, while the second section provides secure mechanical engagement. This multi-functionality is achieved within a single integrated toothing design, avoiding the need for separate components and minimizing structural complexity while maximizing assembly ease.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a toothed shaft system (100) and an assembly method therefor. The toothed shaft system (100) comprises a toothed shaft (10) and a functional element (20) that can be attached to or is attached to the toothed shaft (10). The toothed shaft (10) has external teeth (11) extending parallel to an axis of rotation of the toothed shaft (10), and the functional element (20) has internal teeth (21a, 21b), wherein the external teeth (11) of the toothed shaft (10) and the internal teeth (21) of the functional element (20) are capable of or engage with each other.The toothed shaft (10) and the functional element (20) can be easily assembled into the toothed shaft system by providing that one of the interlocking or engaging toothings (11;21) has first tooth gaps (11a;21a*) and second tooth gaps (11b;21b*) and the other of the interlocking or engaging toothings (21;11) has press-fit teeth (21a;11a*), wherein a backlash-prone fit is formed by the engagement of the press-fit teeth (21a;11a*) in the first tooth gaps (11a;21a*) and a press-fit is formed by the engagement of the press-fit teeth (21a;11a*) in the second tooth gaps (11b;21b*) and adjacent to the first and second tooth gaps (11a,11b;21a*,21b*) a non-gearing section (12) is arranged and/or formed.