Segmented Drive Sprocket with Detachable Polyurethane Teeth
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Solution Overview
Problem
The high production costs and limited flexibility of traditional steel drive sprockets for machines, which require replacement when individual teeth wear out, necessitate a cost-effective and adaptable solution for use in both new and used machines.
Innovation Solution
A drive sprocket design featuring a metal ring with detachable plastic toothed segments, where each segment has an embedded metal corset and a steel base plate with a predetermined bending point, allowing for adjustable diameters and easy replacement of worn segments, paired with a steel drive pinion for reduced costs and improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional steel drive sprockets are used, then strength and durability are improved, but production costs increase and flexibility decreases
Solution Approach 1:
The drive sprocket is divided into a steel ring (providing strength) and detachable plastic toothed segments (reducing cost). The segments can be separately manufactured and replaced, combining the advantages of both materials while avoiding the disadvantages of using entirely steel construction.
Solution Approach 2:
The invention uses a composite structure combining steel (for the ring providing dimensional stability and strength) and plastic (for the toothed segments providing cost-effectiveness and wear resistance). This composite approach optimizes both mechanical properties and manufacturing economics.
2Stability of the object's composition
If traditional steel drive sprockets are used, then structural stability is improved, but adaptability decreases
Solution Approach 1:
By segmenting the toothed portions into detachable plastic segments that can be independently replaced, the system allows easy adaptation to different diameters and wear conditions while the steel ring maintains structural stability. Different numbers of segments can be used to achieve different diameters.
3Reliability
If individual tooth replacement is needed, then wear resistance is improved, but device complexity increases
Solution Approach 1:
The toothed portions are segmented into modular plastic segments that can be independently replaced. When wear occurs, only the affected segments need replacement rather than the entire sprocket, simplifying maintenance while improving wear resistance through material selection.
Solution Approach 2:
The plastic toothed segments are designed as consumable components that can be easily discarded and replaced when worn. This approach is more economical than attempting to repair or recover steel teeth, as the plastic segments are cheaper to replace and their modular design simplifies the replacement process.
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 minimizes production costs, extends equipment lifespan through segment replacement, and enhances operational efficiency by reducing wear and absorbing shock loads, resulting in smoother operation and longer downtimes.
Implementation Method 1
The use of plastic, in particular elastomers, preferably polyurethane for the production of the toothed segments ensures that these have a damping effect during operation, so that the gears are relieved
Implementation Method 2
the toothed segments have an embedded base plate made of metal, the teeth of the toothed segments having an embedded metal corset
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The wheel (1) has toothed segments (4) made of polyurethane and releasably attached to a dimensionally stable ring (3). The ring is made of steel. Teeth of the segments are provided with an embedded metal corset i.e. steel corset. The metal corset is formed from strip material by a two-legged slider. A base plate of the toothed segments is made of steel. The base plate has a predetermined bending point in an area of tooth roots between the teeth of the segments. The ring has punched holes at appropriate places.