Segmented Gear Torsion Spring Tensioning Tool
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Solution Overview
Problem
Existing torsion spring tensioning tools for overhead door counterbalancing mechanisms are complex, require numerous operations for mounting, and are prone to wear, leading to inefficiencies and reduced lifespan.
Innovation Solution
A torsion spring tensioning tool featuring a gear wheel with axially attachable and detachable segments, a simplified design that reduces the necessary space for connection and allows for easy mounting and removal, utilizing a worm and second gear wheel to transmit rotational movement and reduce human effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional tensioning tool with multiple components is used, then the torsion spring can be tensioned, but the tool becomes complex and requires numerous operations for mounting and connection
Solution Approach 1:
The gear wheel is divided into two axially separable segments that can be attached and detached from each other. This segmentation allows the first segment to be mounted on the shaft while the second segment can be attached later, simplifying the mounting process and reducing the number of operations required compared to traditional multi-component tools.
Solution Approach 2:
The housing combines multiple functions into a single structure: it holds the gear mechanism, supports the axially separable gear wheel segments, and provides the fastening means for connecting to the torsion spring. This merging reduces the overall number of separate components compared to traditional tensioning tools.
2Reliability
If a traditional tensioning tool with multiple parts is used, then the torsion spring can be tensioned, but the mounting time increases
Solution Approach 1:
The gear wheel is divided into two axially separable segments that can be attached and detached from each other. This segmentation allows the first segment to be mounted on the shaft while the second segment can be attached later, simplifying the mounting process and reducing the number of operations required compared to traditional multi-component tools.
Solution Approach 2:
The first gear wheel segment is designed to be pre-mounted on the shaft, and the housing is prepared with the gear mechanism in place. This preliminary arrangement allows for quick attachment of the second segment and rapid connection to the torsion spring, significantly reducing mounting time.
3Reliability
If a traditional tensioning tool with multiple components is used, then the torsion spring can be tensioned, but the tool becomes sensitive to wear and has reduced lifespan
Solution Approach 1:
The gear wheel is divided into two axially separable segments that can be attached and detached from each other. This segmentation allows the first segment to be mounted on the shaft while the second segment can be attached later, simplifying the mounting process and reducing the number of operations required compared to traditional multi-component tools.
Solution Approach 2:
The worm gear mechanism provides self-locking capability, maintaining the tensioned state of the torsion spring without requiring continuous external force or complex locking mechanisms. This reduces wear on moving parts and extends tool lifespan.
4Reliability
If a traditional tensioning tool is used, then the torsion spring can be tensioned, but the space required for connection increases
Solution Approach 1:
The housing combines multiple functions into a single structure: it holds the gear mechanism, supports the axially separable gear wheel segments, and provides the fastening means for connecting to the torsion spring. This merging reduces the overall number of separate components and the space required for mounting and operation.
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
Facilitates faster and more robust tensioning of torsion springs, enabling easier installation and maintenance, with a longer tool lifespan and reduced space requirements for mounting, allowing counterbalancing mechanisms to be positioned closer to ceilings.
Implementation Method 1
a gear mechanism adapted to rotate the gear wheel. The gear wheel is adapted to be mounted on a shaft of the counterbalancing mechanism. The gear wheel comprises a fastening means adapted to be connected to the torsion spring of the counterbalancing mechanism and transmit a rotational movement from the gear wheel to the torsion spring
Implementation Method 2
utilizing a worm and second gear wheel to transmit rotational movement and reduce human effort
Data Source
Figure 1
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AI summary
A torsion spring tensioning tool (10) for tensioning a torsion spring of a counterbalancing mechanism of an overhead door. The torsion spring tensioning tool (10) comprises a housing (20), a gear wheel (60) rotatably arranged in the housing (20) and a gear mechanism (40) adapted to rotate the gear wheel (60). The gear wheel (60) is adapted to be mounted on a shaft of the counterbalancing mechanism. The gear wheel (60) comprises a fastening means (91) adapted to be connected to the torsion spring of the counterbalancing mechanism and transmit a rotational movement from the gear wheel (60) to the torsion spring. The gear wheel (60) comprises a first wheel segment (71) and a second wheel segment (72), which second wheel segment (72) is axially attachable to and axially detachable from the first wheel segment (71). The first wheel segment (71) is adapted to be mounted on the shaft of the counterbalancing mechanism when the second wheel segment (72) is in a detached state.