Segmented Sprocket Hub Assembly for Easier Large-Diameter Installation
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Solution Overview
Problem
Large diameter sprockets are difficult to install due to their weight, requiring industrial cranes and being costly to manufacture, and existing segmented sprockets face complications in assembly and may reduce belt life.
Innovation Solution
A segmented sprocket system comprising two or more thin sprockets installed axially on a common hub, with interlocking protrusions and recesses for securement, allowing for easy installation and comparable performance to unitary sprockets without the need for radial fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large diameter sprockets are made as unitary construction, then strength and structural integrity are improved, but weight increases making installation difficult requiring industrial cranes
Solution Approach 1:
The sprocket is divided into multiple thin radial segments that can be assembled together to form the complete large diameter sprocket. Each segment is lightweight and easy to handle, yet when combined they create a structure with sufficient strength and structural integrity for the application.
2Strength
If large diameter sprockets are made as unitary construction, then structural integrity is maintained, but manufacturing cost increases
Solution Approach 1:
The sprocket is divided into multiple thin radial segments that can be assembled together to form the complete large diameter sprocket. Each segment is lightweight and easy to handle, yet when combined they create a structure with sufficient strength and structural integrity for the application.
3Weight of moving object
If radial segmentation is used to reduce weight, then ease of handling is improved, but assembly complexity increases requiring multiple fasteners
Solution Approach 1:
The thin radial segments are designed to nest together on a common hub, with each segment fitting into position alongside the others. This nesting arrangement on the hub provides a natural assembly sequence and positioning mechanism, reducing the need for complex fastening systems while maintaining structural integrity.
4Weight of moving object
If radial segmentation is used to reduce weight, then ease of handling is improved, but belt life decreases
Solution Approach 1:
The thin radial segments are designed to nest together on a common hub, with each segment fitting into position alongside the others. This nesting arrangement on the hub provides a natural assembly sequence and positioning mechanism, reducing the need for complex fastening systems while maintaining structural integrity.
Data Source
AI summary
Segmented sprocket systems and methods for installing the segmented sprocket systems for use in numerous different applications such as, but not limited to, industrial sprockets. The present invention may be a segmented sprocket system including two or more relatively thin sprockets (100) that are installed together on a common hub (200) such that the two or more sprockets form a composite sprocket having a width approximately equal to the sum of the width of the individual sprockets. A segmented sprocket system may include a hub; at least two sprockets having the same outer diameter and an interior opening having a diameter approximately equal to the outer diameter of the hub; wherein the at least two sprockets are positioned on the hub such that each sprocket abuts a neighboring sprocket, thus resulting in a composite sprocket structure.