Segmented Helical Gear Assembly for Even Stress Distribution
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Solution Overview
Problem
Conventional gear designs with helical toothing often experience mechanical stress buildup due to protrusions and recesses, leading to reduced service life and torque transmission efficiency.
Innovation Solution
A gear composed of segments with helical toothing, where the outermost tooth is flush with the connecting surface, and screws pass through these surfaces, distributing tension evenly and avoiding protrusions or recesses, while using struts and flange regions for enhanced stability and torque transmission with minimal material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outermost tooth protrudes beyond the connecting surface in conventional gear designs, then the helical toothing can be formed, but mechanical stress builds up and service life is reduced
Solution Approach 1:
Instead of allowing the tooth to protrude beyond the connecting surface as in conventional designs, the patent inverts the arrangement by making the tooth flush with or recessed relative to the connecting surface. This reversal eliminates the stress concentration caused by protrusions while maintaining the helical toothing configuration, thereby resolving the contradiction between strength and service life.
Solution Approach 2:
The patent converts the potential harm of having a tooth that might protrude into a benefit by deliberately designing the tooth to be flush with or recessed from the connecting surface. This design choice transforms what could be a stress concentration point into a stress-distributing feature, allowing the gear to achieve both high strength and extended service life.
2Stability of the object's composition
If more material is used to increase stability and torque transmission, then stability and torque capacity improve, but material usage and weight increase
Solution Approach 1:
The gear is divided into multiple segments that are connected through optimized flange and strut structures. This segmentation allows each component to be efficiently designed for its specific function, providing high stability and torque transmission capacity while minimizing overall material usage compared to a solid monolithic structure.
Solution Approach 2:
The patent applies different structural qualities to different regions: the flange regions are designed with sufficient thickness for connection stability, while the strut regions are optimized for torque transmission with minimal material. This local optimization ensures high overall stability without excessive material consumption throughout the entire structure.
3Shape
If the tooth protrudes beyond the surface region, then helical toothing is achieved, but tension forces are unevenly distributed
Solution Approach 1:
The patent inverts the conventional arrangement by making the tooth flush with or recessed from the connecting surface rather than protruding. This reversal maintains the necessary helical toothing geometry while ensuring that tension forces are evenly distributed across the flange region, eliminating the stress concentration that would occur with a protruding tooth configuration.
Data Source
AI summary
A gear is composed of segments, and each segment includes a support region, a first flange region which is arranged at the front in the circumferential direction, and a second flange region which is arranged at the rear in the circumferential direction. A first surface region of the first flange region of each segment lies against the second surface region of the second flange region of the next adjacent segment to the respective segment, and at least one screw which passes through the first flange region of the respective segment and the flange region of the respective next adjacent segment connects the segments. A toothing is introduced into the support region of the segment, and the toothing is arranged as helical toothing. The first surface region extends parallel to the tooth, which is next adjacent to the surface region, of the toothing of the respective segment.