Segment Variator for Harvesting Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing segment variators for self-propelled harvesting machines are costly to produce, prone to noise and vibration at high speeds, and require complex assembly due to their design, which affects the smooth operation and torque transmission of V-ribbed belts.
Innovation Solution
A segment variator with groove segments of varying lengths and a radial adjustment mechanism that allows for a smooth transition between open and closed states, reducing vibration and noise by superimposing waves of different frequencies, and using segment blocks connected to form a continuous outer contour for reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If groove segments are spaced apart in the circumferential direction to form an open state, then the diameter of the running surface increases allowing higher speed operation, but the drive means sinks and swings in the gap areas causing noise and vibration
Solution Approach 1:
The groove segments are designed with asymmetric outer contours that are rounded inward in the radial direction. This asymmetric rounding prevents the drive means from sinking into the gaps between segments while maintaining the open state for high-speed operation, thereby eliminating the noise and vibration caused by drive means contact with sharp edges
Solution Approach 2:
The outer contours of the groove segments are pre-rounded inward to create a cushioning effect that prevents the drive means from making harsh contact with the segment edges during operation. This prior cushioning design eliminates vibration and noise before they can occur during high-speed operation
2Power
If a large number of groove segments are used to increase torque transmission capacity, then the power transmission capability increases, but the number of components and assembly effort increases
Solution Approach 1:
Multiple groove segments are connected to one another in the axial direction to form segment blocks. This merging reduces the total number of separate components while maintaining the necessary number of grooves for high torque transmission, thereby simplifying assembly and reducing manufacturing complexity
3Ease of manufacture
If groove segments are connected to form segment blocks, then the number of components is reduced and assembly is simplified, but the smoothness of the outer contour may be compromised
Solution Approach 1:
The segment blocks are designed with asymmetric outer contours featuring inward rounding that creates a visually smooth and continuous appearance. This asymmetric design maintains aesthetic smoothness while allowing multiple segments to be connected, balancing manufacturing simplicity with shape quality
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
The solution enables efficient torque transmission with reduced noise and vibration, extending the service life of the drive means and allowing for continuous speed adjustment without additional reduction gears, while being cost-effective and simpler to assemble.
Implementation Method 1
the groove segments being adjustable in a radial direction to the axis or back by moving the base body in or against the axial direction relative to the shaft mount
Implementation Method 2
the friction occurring at the V-ribs determines the torque that can be transmitted with the belt
Implementation Method 3
reducing vibration and noise by superimposing waves of different frequencies
Data Source
Figure 1
Figure 2(a)
Figure 2(b)
AI summary
The present invention relates to a segment variator for a self-propelled harvesting machine or implement, comprising a base body and a shaft receptacle arranged concentrically around an axis and displaceable relative to each other in and against an axial direction, and a running surface for a drive element having several axially arranged running grooves and formed from a plurality of circumferentially separated groove segments, wherein the groove segments are adjustable by displacing the base body in or against the axial direction relative to the shaft receptacle against a radial direction to the axis or back, wherein the segment variator thereby reversibly adjusts from an open state in which the groove segments are spaced apart from each other in the circumferential direction to a closed state in which the running surface is closed and the groove segments are arranged adjacent to each other in the circumferential direction.wherein the axially adjacent groove segments are at least partially arranged circumferentially rotated relative to each other by an angle of rotation, and/or the groove segments are at least partially of different lengths. The present invention further relates to a self-propelled harvesting machine or implement, in particular a forage harvester or a combine harvester, with such a segment variator. The present invention further relates to the use of such a segment variator.