Power Tool Coupling With Cambered Gears for Axial Misalignment
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Solution Overview
Problem
Modular electric power tools face challenges in adapting power transmission to different modules due to rigid designs that do not accommodate axial misalignment, leading to potential stress and inability to replace components for varying applications.
Innovation Solution
An electric power tool design featuring a coupling with a cambered profile for the motor and input gears, allowing tilting movement and easy adaptation to different module lengths, along with a housing that houses the motor, motor gear, coupling, and input gear, providing improved tolerance to axial misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the power transmission is made rigid to transmit torque efficiently with minimal losses, then energy loss is reduced, but the tolerance to axial misalignment deteriorates
Solution Approach 1:
The coupling is designed with dynamic flexibility through the cambered profile on at least one gear, allowing the coupling to tilt and adapt to axial misalignment while maintaining torque transmission. This dynamic adaptation resolves the contradiction by enabling the rigid power transmission to accommodate misalignment without excessive stress.
Solution Approach 2:
The cambered profile changes the geometric parameter of the gear tooth, creating a gradual slope that allows tilting movement. This parameter change enables the coupling to adjust its angle relative to the motor shaft, providing tolerance to axial misalignment while maintaining efficient torque transmission.
2Loss of energy
If the power transmission is designed as a fixed rigid structure, then torque transmission efficiency is improved, but adaptability to different module sizes deteriorates
Solution Approach 1:
The coupling is segmented into a motor gear portion, a shaft portion, and an input gear portion. This segmentation allows the shaft portion to be independently replaced with different lengths to adapt to different module sizes, while the cambered profile segments maintain efficient torque transmission through tilting capability.
Solution Approach 2:
The coupling incorporates dynamic tilting capability through the cambered profile, allowing it to adapt its angle to different module configurations. This dynamic feature enables the same coupling design to work with various module sizes while maintaining torque transmission efficiency.
3Adaptability or versatility
If modular components are used to allow easy replacement, then ease of repair and adaptability are improved, but the power transmission becomes more complex
Solution Approach 1:
The power transmission is segmented into modular components: motor gear, coupling with shaft portion, and input gear. The coupling itself is segmented into functional parts that can be independently replaced. This segmentation enables modular replacement while keeping each individual component relatively simple in design.
Solution Approach 2:
The coupling design serves multiple functions: torque transmission, accommodation of axial misalignment through tilting, and adaptability to different module sizes through shaft portion replacement. This multi-functionality reduces the need for separate specialized components, thereby reducing overall system complexity despite modular capabilities.
Data Source
AI summary
An electric power tool includes an electric motor with a motor gear, an output shaft with an input gear, a coupling that connects the motor gear to the input gear, and a housing that houses the motor, the motor gear, the coupling and the input gear. The coupling includes a shaft portion and two connective portions arranged at opposite ends of the shaft portion for connection to the motor gear and input gear, respectively. The motor gear and the input gear, each, have a cambered profile allowing a tilting movement of the coupling with respect to an axial position of one of the motor gear and the input gear that has a cambered profile.