Sorting Module Shaft Mounting to Prevent Gear Misalignment
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Solution Overview
Problem
Existing sorting devices suffer from unstable connections between shaft rods and sorting supports, leading to misaligned gear meshing and reduced gear service life due to the use of through holes with larger apertures, causing 'trapezoidal meshing' issues.
Innovation Solution
A sorting module design that includes a sorting support with specific mounting ports and a limiting structure to stabilize the shaft rod, ensuring it is fixed in intersecting directions, preventing misalignment of gears during meshing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If through holes with larger apertures are used for mounting shaft rods, then ease of installation is improved, but connection stability deteriorates causing shaft rod misalignment
Solution Approach 1:
A positioning plate is introduced as an intermediary component between the shaft rod and the sorting support. The positioning plate includes a positioning hole that fits the shaft rod and mounting holes for screws, serving as a mediator that ensures precise positioning and stable connection without requiring large apertures in the sorting support itself.
Solution Approach 2:
The positioning plate is pre-formed with precisely positioned positioning holes and mounting holes before installation. This preliminary preparation ensures that when the shaft rod is installed, it is automatically positioned correctly, and the screws can be mounted without requiring large apertures in the sorting support, thus maintaining both ease of installation and connection stability.
2Ease of manufacture
If shaft rod positions are not precisely limited, then ease of assembly is improved, but gear meshing alignment deteriorates causing trapezoidal meshing
Solution Approach 1:
The positioning plate serves as a precision intermediary that carries the precise positioning geometry. The positioning hole in the positioning plate is manufactured with high precision to ensure correct shaft rod positioning, while the plate itself can be easily assembled to the sorting support through standard mounting holes, thus separating the precision requirement from the assembly complexity.
Solution Approach 2:
The mounting system is segmented into the positioning plate and the sorting support. The precision requirements are concentrated in the positioning plate's positioning hole, while the sorting support only needs standard mounting features. This segmentation allows high precision to be achieved in one component without making the entire assembly complex.
3Device complexity
If simple mounting methods are used, then device complexity is reduced, but connection reliability deteriorates leading to unstable shaft rod positions
Solution Approach 1:
The positioning plate is a simple intermediary component that dramatically improves reliability. It includes a positioning hole for precise shaft rod positioning and mounting holes for secure attachment to the sorting support. This simple plate structure provides both precision and stability without adding significant complexity to the overall mounting system.
Data Source
AI summary
A sorting module includes a sorting support, a mounting port, a transmission mechanism and a limiting structure. The sorting support includes a bottom plate and two side plates provided on opposite sides of the bottom plate. The mounting ports are respectively provided at the two side plates, and the mounting ports include a first mounting port and a second mounting port communicated with each other. The transmission mechanism includes a shaft rod mounted on the first mounting port, and the shaft rod is fixed relative to the first mounting port. The first mounting port has a first direction for inserting the shaft rod, and the shaft rod abuts against and limits the opposite side walls of the first mounting port in a second direction. The limiting structure is provided at the second mounting port to abut against and limit the shaft rod in the first direction.