Segmented Elastic Sprocket Structure for Roller Chain Noise Reduction
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Solution Overview
Problem
Existing sprocket designs face challenges in reducing noise from engagement with roller chains, with annular elastic bodies requiring different diameters increasing production costs and columnar elastic bodies complicating attachment, while also increasing production costs and complicating the attachment process.
Innovation Solution
A sprocket design featuring tooth grooves with through holes and partially-circular side plate portions connected by elastic bodies, allowing for contact with the roller chain, with the ability to divide the elastic bodies at connecting portions to simplify attachment and reduce production costs by using fewer types of elastic bodies for different sprocket sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If annular elastic bodies with different diameters are used for sprockets of different sizes, then noise reduction is achieved, but production cost increases due to needing multiple types of elastic bodies
Solution Approach 1:
The elastic body is divided into multiple arc-shaped sections that can be assembled together to form complete elastic bodies of different diameters. This segmentation allows a single type of elastic body section to be used across multiple sprocket sizes, reducing the need to manufacture multiple types of elastic bodies while maintaining noise reduction effectiveness.
Solution Approach 2:
The arc-shaped elastic body sections are designed with universal applicability, where the same type of section can be used to create elastic bodies for sprockets of various diameters. This multi-functionality eliminates the need for size-specific elastic body designs, thereby reducing production costs while still achieving noise reduction across different sprocket configurations.
2Ease of manufacture
If columnar elastic bodies are used, then production cost is reduced by using the same member for different sprocket sizes, but attachment work becomes complicated
Solution Approach 1:
The elastic body is segmented into arc-shaped sections that are specifically designed to fit within the tooth grooves of the sprocket. This segmentation simplifies the attachment process compared to columnar elastic bodies, as the arc-shaped sections naturally align with the circumferential arrangement of the teeth and can be easily positioned and secured in place.
Solution Approach 2:
The elastic body is designed with arc-shaped sections that have local quality optimized for engagement with the roller chain at specific locations. Each arc-shaped section is positioned to contact the roller chain at the appropriate point, ensuring effective noise reduction while maintaining a simple attachment process that does not require complex positioning procedures.
3Object-affected harmful factors
If multiple types of elastic bodies are prepared for different sprocket sizes, then noise reduction is optimized, but productivity decreases due to increased attachment steps
Solution Approach 1:
The elastic body is divided into multiple arc-shaped sections that can be assembled from a single type of component. This segmentation enables the use of identical elastic body sections across different sprocket sizes, reducing the variety of parts that need to be managed and attached. Consequently, the attachment process becomes more standardized and efficient, improving productivity while maintaining noise reduction performance.
Solution Approach 2:
The arc-shaped elastic body sections are designed with universal characteristics that allow them to be used across different sprocket configurations. This universality reduces the number of different elastic body types that need to be prepared and attached, streamlining the manufacturing process and improving productivity without compromising the noise reduction effectiveness.
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 design effectively reduces noise from sprocket-roller chain engagement, allows for low-cost production with fewer elastic body types, and simplifies the attachment process by reducing the number of steps required, improving productivity.
Implementation Method 1
a plurality of elastic bodies provided in the sprocket body, to be contactable with the roller chain
Data Source
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AI summary
According to the sprocket to be provided, noise due to the engagement with a roller chain can be reduced, sprockets different in the number of teeth and the diameter can be produced at low cost without increase in the types of elastic bodies, and the number of steps in attachment work of elastic bodies is decreased, thereby improving productivity. [Means for solving the problem] A sprocket includes a sprocket body 2 provided with through holes 5 corresponding to tooth grooves 4, and a plurality of elastic bodies 20, 30 provided in the outer circumferential portion of the sprocket body 2. The elastic body 20 includes a pair of partially-circular shape side plate portions 21A, 21B provided on the respective side surfaces of the sprocket body 2, and a connecting portion 22 attached to three adjacent through holes 5 to connect the side plate portions 21A, 21B. The elastic body 20 is divided into divided bodies 20A, 20B at the connecting portion 22. The elastic body 30 includes a pair of partially-circular shape side plate portions 31A and 31B provided on the respective side surfaces of the sprocket body 2, and a connecting portion 32 attached to two adjacent through holes 5 to connect side plates 31A, 31B. The elastic body 30 is divided into divided bodies 30A, 30B at the connecting portion 32.