Reduction Gear Box with Flat Gear Torque Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing reduction gear boxes with integrated rotation direction converting and reduction units face challenges in smooth operation due to misalignment of input and intermediate shafts, leading to noise, backlash, and increased structural size requirements, making unitization and separation of these components difficult.
Innovation Solution
The reduction gear box is designed to be assembled from separate rotation direction converting and reduction units, with the intermediate and crank shafts coupled for torque transmission and axial movement, using spline or flat gear couplings, allowing for precise positional relationship maintenance without requiring additional adjustments during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the rotation direction converting unit and reduction unit are integrated into a single structure, then the overall structure is more compact, but the alignment precision between input shaft and intermediate shaft deteriorates, causing noise and backlash
Solution Approach 1:
The reduction gear box is divided into separate rotation direction converting unit and reduction unit, each with independently supported shafts. The input shaft is supported in the rotation direction converting unit while the intermediate shaft is supported in the reduction unit, allowing each shaft to be precisely positioned in its own unit without interference from integration errors.
2Ease of manufacture
If the rotation direction converting unit and reduction unit are separated into independent units, then the manufacturing and assembly process is simplified, but the structural complexity increases
Solution Approach 1:
A coupling mechanism serves as an intermediary between the intermediate shaft and crank shaft, enabling torque transmission while accommodating axial movement. This coupling allows the units to be manufactured and assembled separately while maintaining precise shaft alignment and preventing axial force application, thus simplifying manufacturing without significantly increasing structural complexity.
3Manufacturing precision
If additional adjustment mechanisms are added during assembly to maintain precise positional relationships, then the alignment precision is improved, but the device complexity and assembly time increase
Solution Approach 1:
The precise positional relationships and meshing states are predetermined during the design and manufacturing phases. The coupling mechanism is pre-configured to maintain the desired axial distance between the intermediate shaft and crank shaft, eliminating the need for additional adjustment mechanisms during assembly while preserving high alignment precision.
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
This design simplifies the manufacturing process by allowing separate assembly and integration of units, maintaining desired pressure and meshing states, and preventing axial force application, thus reducing noise and structural complexity.
Implementation Method 1
the intermediate shaft and the crank shaft are joined by a spline coupling so that torque can be transmitted from the intermediate shaft to the crank shaft, and that the intermediate shaft may move in the axial direction of the crank shaft
Implementation Method 2
the intermediate shaft and the crank shaft are joined by flat gears that rotate around an axis line parallel to the intermediate shaft and the crank shaft, such that torque can be transmitted from the intermediate shaft to the crank shaft
Implementation Method 3
the crank shaft having an eccentric cam that engages with the external gear and causes the external gear to revolve orbitally in the internal gear by revolving eccentrically
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a reduction gear box comprising a rotation direction converting unit (217) and a reduction unit (218), wherein the rotation direction converting unit comprises a first pedestal (212) including a first flat face (230), an input shaft supported rotatably in the first pedestal, an intermediate shaft (266) supported rotatably in the first pedestal in a position substantially orthogonal to the input shaft, a first gear (234) that rotates integrally with the input shaft (235), and a second gear (244) that meshes with the first gear and rotates integrally with the intermediate shaft, wherein the input shaft is coupleable to an output shaft of a motor, and the reduction unit comprises a second pedestal (258) including a second flat face making surface contact with the first flat face, an internal gear (252), an external gear (254) housed within the internal gear, and a crank shaft (260) supported in the second pedestal, wherein the crank shaft being configured to rotate with respect to the second pedestal and incapable of moving in its axial direction, the crank shaft having an eccentric cam (261) that engages with the external gear and causes the external gear to revolve orbitally in the internal gear by revolving eccentrically, wherein the rotation direction converting unit and the reduction unit are joined together, by being fixed while the first flat face and the second flat face are in a state of making surface contact, and in this positional relationship the intermediate shaft and the crank shaft are coupled via a plurality of flat gears (268,270,272,274) and configured to transmit torque, the plurality of gears comprises a first gear (268) which is fixed to the crank shaft, a second gear (270) to which said first gear is engaged, and a third gear (272) which is fixed to the intermediate shaft and meshes with a gear (274) that is fixed to the second gear, and rotation generated by either the internal gear or the external gear with the rotation of the input shaft is transmitted to an output rotation member.