Roller Reducer Flange Rings Reduce Bending and Slip
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Solution Overview
Problem
Existing planetary gear reducers with stepped threaded rollers face issues such as roller bending, reduced load-bearing capacity, increased slip, and inefficient torque transmission due to edge contact and persistent play in thread interfaces, which limits their performance and service life.
Innovation Solution
The introduction of flange rings with diameters matching the effective thread diameters of the rollers and shaft, allowing for rotational sliding and redistributing load radially, reduces bending and friction, enhancing efficiency and load-bearing capacity while maintaining play-free transmission across a wide range of gear ratios without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rollers transmit high torque through threaded engagement with the shaft, then torque transmission capability is improved, but roller bending occurs in the central part leading to edge contact and decreased load-bearing capacity
Solution Approach 1:
A flange ring is introduced as an intermediary component between the roller and the shaft. The flange ring receives the radial component of the thread contact force and transfers it directly to the shaft, preventing roller bending while maintaining torque transmission capability through the threaded engagement.
Solution Approach 2:
The load transmission path is extended from a single axial dimension to include a radial dimension. The flange ring creates a new load path in the radial direction, allowing the radial component of thread contact force to be directly transferred to the shaft without causing roller bending.
2Manufacturing precision
If nuts of each member are pressed together to eliminate play in thread interfaces, then play elimination is achieved, but roller slip occurs and play persists
Solution Approach 1:
The flange ring acts as a mediator that provides a stable reference surface for the roller. This prevents roller slip by ensuring proper alignment and contact, allowing the thread interfaces to remain play-free without causing roller slip that would compromise transmission reliability.
3Strength
If flange rings are added to reduce roller bending and redistribute load, then load-bearing capacity and efficiency are improved, but device complexity increases
Solution Approach 1:
The flange ring performs multiple functions simultaneously: it supports the roller to prevent bending, receives and redirects radial loads to the shaft, maintains proper alignment to prevent slip, and enables efficient torque transmission. This multi-functionality justifies the addition of the component by eliminating multiple problems with a single element.
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 configuration significantly reduces roller and shaft bending, minimizes slip, increases efficiency, and extends the service life of the reducer by redistributing load radially, ensuring stable performance across varying loads and gear ratios.
Implementation Method 1
rotational sliding and redistributing load radially, reduces bending and friction
Implementation Method 2
at least one roller flange ring arranged adjacent to the roller thread portions to rotationally slide against the corresponding at least one flange ring of the shaft
Data Source
AI summary
The present invention relates to a roller reducer comprising a transmission gear having an externally threaded shaft having at least one left-handed thread portion, at least one right-handed thread portion, and at least one shaft flange ring, and a plurality of rollers, each roller having a plurality of thread portions, comprising at least one left-handed thread portion and at least one right-handed thread portion, each thread portion arranged to engage with the respective thread portions of the shaft, and at least one roller flange ring arranged adjacent to the roller thread portions to rotationally slide against the corresponding at least one flange ring of the shaft.Diameters of the flange rings of the rollers and the flange rings of the shaft are each equal to the respective effective thread diameters of the engaged thread portions of the rollers and the shaft, respectively.