Rack and Pinion Coupler Assembly for Alignment
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Solution Overview
Problem
Misalignment of rack and pinion components in power transmission systems leads to premature wear, inaccuracies, and excessive noise, with existing shimming methods being tedious and prone to errors.
Innovation Solution
A coupler assembly with a floating mount and adjustable clamp members that allows for selective adjustment of the pinion's pitch and yaw, enabling precise alignment with the rack, and a method involving insecure and secure clamping to optimize meshing alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shims are used during assembly to improve meshing accuracy of rack and pinion, then alignment precision is improved, but assembly complexity and time increase significantly
Solution Approach 1:
The patent introduces a coupler assembly as an intermediary component between the rack and pinion that provides adjustable alignment. This coupler includes mounting plates with adjustable features that allow precise positioning of the pinion relative to the rack without requiring complex shimming procedures. The intermediary coupler simplifies the assembly process while achieving the desired meshing accuracy.
2Manufacturing precision
If shimming is performed to correct misalignment, then meshing precision is improved, but assembly time and labor increase
Solution Approach 1:
The coupler assembly is pre-configured with adjustable mounting features and alignment mechanisms during manufacturing. This preliminary preparation allows for quick field adjustment of the pinion alignment relative to the rack without requiring time-consuming shimming operations during assembly. The adjustable design enables rapid correction of any misalignment issues.
3Ease of manufacture
If rigid fixed mounting is used for pinion and rack, then assembly simplicity is maintained, but misalignment causes premature wear and noise
Solution Approach 1:
The coupler assembly incorporates adjustable and potentially movable features that allow the pinion mounting position to be optimized relative to the rack. This dynamic adjustment capability ensures proper meshing alignment while maintaining assembly simplicity. The system can be adjusted to compensate for manufacturing tolerances and maintain reliable operation throughout the component lifecycle.
Data Source
AI summary
A coupler assembly is provided for coupling components in a power transmission system, such as a rack and pinion drive system. The coupler assembly includes a floating mount and a pair of clamp members movable between an unfastened configuration in which the floating mount is adjustably supported between the clamp members and a fastened configuration in which the floating mount is fixedly secured between the clamp members. At least a pitch and a yaw of the floating mount are adjustable when the clamp members are in the unfastened configuration. Methods and systems which relate to or include the aforementioned coupler assembly are also provided.