Rack-Pinion Backlash Adjustment Using Multi-Position Measurement
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Solution Overview
Problem
The existing methods for adjusting backlash between a pinion and a rack in rack-pinion drives are cumbersome and require manual effort, especially when dealing with heavy or bulky assemblies, and often result in larger than necessary backlash due to the need to find the highest points of the rack and pinion.
Innovation Solution
A process that involves positioning the motor-gearbox assembly in a first radial distance, determining circumferential backlash at multiple positions along the rack, calculating a minimal backlash, and adjusting the radial distance to achieve optimal alignment without pre-tensioning, eliminating the need to find the highest points and allowing for manual or automated adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the traditional method of finding the highest points of the rack and pinion is used to adjust backlash, then the backlash can be minimized at that specific configuration, but the adjustment process becomes cumbersome and requires considerable manual action
Solution Approach 1:
The patent replaces the traditional mechanical method of finding highest points by hand with an automated measurement system that uses sensors to detect the actual highest points of the rack and pinion teeth. This substitution of mechanical manual operation with an automated sensing and control system resolves the contradiction by maintaining precision while dramatically improving ease of operation.
Solution Approach 2:
The measurement system automatically identifies the highest points and calculates the required adjustment without human intervention. The system serves itself by using its own sensors and processors to determine the optimal positioning, eliminating the need for manual searching and judgment.
2Manufacturing precision
If the motor-gearbox assembly is adjusted to minimize backlash at the highest points configuration, then backlash is minimized at that position, but the assembly becomes difficult to fix especially if heavy or bulky
Solution Approach 1:
The patent performs the precise positioning adjustment before final fixation of the assembly. The measurement system determines the exact radial adjustment needed, and the assembly is positioned accordingly before being secured. This preliminary positioning action prevents the need to handle and reposition heavy assemblies multiple times during adjustment.
Solution Approach 2:
The patent replaces manual positioning and fixation operations with an automated measurement and control system that calculates and guides the precise radial adjustment. This substitution makes the process easier and more accurate, especially for heavy or bulky assemblies that are difficult to manipulate manually.
3Manufacturing precision
If the radial distance is adjusted based on circumferential backlash measurements at multiple positions, then the alignment precision between rack and pinion is improved, but the measurement and adjustment process time increases
Solution Approach 1:
The measurement system continuously measures circumferential backlash at multiple positions around the pinion circumference without interruption. The processor continuously processes these measurements and calculates the optimal radial adjustment in real-time, maintaining continuous useful action throughout the adjustment process rather than using discrete, time-consuming manual measurements.
Solution Approach 2:
The patent replaces time-consuming manual measurements at multiple positions with an automated sensor system that rapidly captures backlash data at multiple circumferential positions simultaneously or in quick succession. The electronic processing and calculation are much faster than manual methods, achieving high alignment precision without proportionally increasing adjustment time.
Data Source
AI summary
In a process for the adjustment of backlash between a pinon (20) and a rack (10) in a rack-pinion drive, a motor-gearbox assembly (30) including a motor and a gearbox is supported on a carrier (40) via a positioning mechanism (42) for precisely positioning the assembly (30) in a radial position relative to the rack (10). In the process, the assembly (30) is positioned in a first radial distance relative to the rack (10), using the positioning mechanism (42) and a first circumferential backlash between the pinon (20) and the rack (10) is determined at a first position of the pinion (20) along the rack (10), based on measurements taken on an input side of the gearbox. Then, the assembly (30) and/or the rack (10) are positioned in a second position of the pinion (20) along the rack (10), different from the first position, and a second circumferential backlash between the pinon (20) and the rack (10) is determined at the second position, based on measurements taken on the input side of the gearbox A minimal circumferential backlash is determined from the determined first circumferential backlash and the determined second circumferential backlash (and possibly further measurements), and a radial adjustment distance is determined based on the determined minimal circumferential backlash. Finally, the motor-gearbox assembly (30) is repositioned in a radial direction, towards the rack (10), by the determined radial adjustment distance, using the positioning mechanism (42).