Rack-and-Gear Carrier Transfer for Fast, Precise Positioning
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Solution Overview
Problem
Existing component carrier transmission systems, primarily driven by linear actuators or servo modules, face limitations in transmission speed, positioning accuracy, and payload capacity, particularly in applications like welding and crimping, due to mechanical structure constraints and cumulative tolerance issues.
Innovation Solution
A carrier transmission device comprising a slide rail, a rack, and a pair of gears, where the rack is connected to the carrier and engages with the gears to drive movement along the slide rail, with a blocking device reducing tooth clearance for improved accuracy and a servo motor-driven mechanism for adjustable rotation speed and transmission ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If linear actuators or cylinders are used for carrier transmission, then the mechanical structure is simple, but the transmission speed and positioning accuracy are insufficient
Solution Approach 1:
The patent replaces traditional linear actuators and cylinders with a rack and pinion gear mechanism. The rack is linearly disposed and engages with a rotationally disposed gear, converting rotational motion to linear motion. This substitution achieves higher positioning accuracy through the gear engagement mechanism while maintaining mechanical simplicity.
Solution Approach 2:
The patent employs periodic engagement and disengagement of the gear with the rack to achieve sequential carrier transmission. The gear rotates in periodic cycles, engaging with the rack at specific intervals to propel carriers forward, then disengaging to allow the next carrier to be positioned. This periodic action enables precise control over transmission speed and positioning accuracy.
2Speed
If dual servo modules are used to transport multiple carriers, then the transmission speed improves, but the cumulative tolerance and positioning accuracy deteriorate
Solution Approach 1:
The patent merges multiple carrier transmission functions into a single integrated rack and pinion system. Instead of using separate servo modules for each carrier, one gear engages with the rack to simultaneously control the motion of multiple carriers that are linearly disposed along the rack. This eliminates cumulative tolerance errors that would arise from multiple independent servo modules while maintaining high transmission speed.
3Device complexity
If traditional mechanical transmission systems are used, then the structure is simple, but the payload capacity for welding and crimping applications is insufficient
Solution Approach 1:
The patent segments the transmission system into distinct functional components: the rack that supports multiple carriers, the pinion gear that provides rotational drive, and the engagement mechanism that transfers force. This segmentation allows each component to be optimized for its specific function, enabling the system to handle higher payload capacities for welding and crimping applications while maintaining structural simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances transmission efficiency and accuracy by allowing simultaneous engagement of gears with the rack, improving positional precision and accommodating higher payload requirements through synchronized gear rotation and adjustable speed control.
Implementation Method 1
The pair of gears are spaced by a predetermined distance in the transmission direction and are adapted to engage with the rack and drive the carrier to move in the transmission direction on the slide rail
Data Source
AI summary
A carrier transmission device comprises a slide rail, a rack and a pair of gears. The slide rail extends along a transmission direction of a carrier to be transmitted and is adapted to slidingly guide the carrier. The rack extends along the transmission direction and is connectable to, or integrally formed on, the carrier. The pair of gears are spaced by a predetermined distance in the transmission direction and are adapted to engage with the rack and drive the carrier to move in the transmission direction on the slide rail.