Ribbed Gear Wheel Structure for Axial Rigidity and Low Weight
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Solution Overview
Problem
Gear wheels face challenges in achieving high axial rigidity and radial load capacity while minimizing weight and installation space, particularly with helical gear teeth that experience high axial loads, leading to potential deformation and increased noise and wear.
Innovation Solution
A gear wheel design featuring ribs that extend along tangents to a tangent circle, with a rib thickness and diameter configuration that maximizes torsional rigidity, combined with a multi-component structure using metal and high-performance plastics for optimal load distribution and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the width of the gear wheel is increased to counteract deformations from axial loads, then the axial rigidity is improved, but the weight and installation space increase
Solution Approach 1:
The gear wheel is divided into multiple ribs arranged radially, creating a segmented structure that provides axial rigidity without requiring a solid disk design. This segmentation allows material to be placed only where structurally necessary, reducing overall weight while maintaining stability against axial deformation.
Solution Approach 2:
The rib design implements local quality by concentrating material in specific radial and circumferential positions where it most effectively resists axial loads. The ribs are positioned and dimensioned to provide maximum rigidity at critical locations rather than uniformly distributing material throughout the entire gear wheel, thereby minimizing weight.
2Stability of the object's composition
If the width of the gear wheel is increased to counteract deformations from axial loads, then the axial rigidity is improved, but the installation space increases
Solution Approach 1:
The segmented rib structure achieves the required axial rigidity with a more compact overall diameter compared to a solid disk design. By placing material only in the ribs rather than throughout the entire width, the gear wheel occupies less installation space while maintaining the necessary structural stability.
Solution Approach 2:
The local concentration of material in the ribs provides maximum rigidity with minimum material usage, allowing the gear wheel to achieve the required performance in a smaller footprint. This localized reinforcement strategy reduces the overall installation space requirement compared to uniform thickening.
3Stability of the object's composition
If conventional rib designs with parabolic base are used to increase axial rigidity, then the axial deformation is reduced, but the manufacturing complexity increases due to unfavorable flow paths
Solution Approach 1:
The rib design incorporates optimized curvature profiles that improve material flow during injection molding compared to conventional parabolic bases. The curved transitions in the rib structure guide plastic flow more effectively, reducing air traps and voids while maintaining the axial rigidity benefits of the rib configuration.
Solution Approach 2:
The rib geometry parameters (cross-sectional shape, thickness distribution, curvature radius) are optimized to balance structural performance with manufacturability. By adjusting these parameters, the design achieves both good axial rigidity and favorable flow paths for injection molding, improving manufacturing quality.
4Strength
If ribs with convex and concave sections are used to increase axial rigidity, then the axial strength is improved, but the radial load capacity is limited due to bending moments
Solution Approach 1:
The rib cross-section employs asymmetric geometry with the convex side facing the gear rim and the concave side facing the hub. This asymmetric configuration optimizes the rib for resisting axial loads while minimizing bending moments under radial loading, thereby improving both axial strength and radial load capacity simultaneously.
Solution Approach 2:
The convex-concave rib profile creates local quality variations that are optimized for different loading directions. The convex portion provides enhanced axial strength, while the concave portion reduces stress concentration and bending moments under radial loads, achieving a balanced performance for both axial and radial force transmission.
Data Source
AI summary
The present invention relates to a gear wheel comprising an outer part (12) having a gear rim (14), an insert (16) which has an insert outer diameter (dEa) and a receptacle section (32) having an insert part inner diameter (dEi) for forming a shaft-hub connection, and a connecting part (18) which is arranged between the insert part (16) and the outer part (12) and which connects the insert part (16) and the outer part (12) in a formfitting and/or materially-bonded and/or friction-locked manner, wherein the connecting part (18) has a number of ribs (27) or the connecting part (18) is formed by a number of ribs (27), wherein the ribs (27) each extend along a tangent (T) which abuts a tangent circle (CT), wherein the tangent circle (CT) has a tangent circle diameter (dCT) which is larger than or equal to the insert inner diameter (dEi) and smaller than or equal to the insert outer diameter (dEa).