Speed Modulation Gearbox With Stepped Idler Gears for Ratio Flexibility
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Solution Overview
Problem
Existing drive devices with planetary gears and auxiliary drives require complex and costly modifications to adapt to varying speed ratios and control ranges, especially for retrofitting in existing systems, and lack efficient speed control solutions.
Innovation Solution
The drive device employs a gear chain with stepped intermediate spur gears for parallel arrangement of spur gear pairings, allowing constant center distances and wheel diameters, enabling flexible transmission ratios without altering the housing structure, and incorporates auxiliary drives with constant transmission ratios and clutches for emergency operation, reducing costs and installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the diameter of spur gears is adapted to specific application requirements for varying speed ratios, then the desired gear ratios and control range can be achieved, but the design becomes very complex and incurs high costs
Solution Approach 1:
The transmission system is segmented into a fixed-ratio planetary gear set and variable-speed auxiliary drives. The planetary gear set provides a constant base ratio, while the auxiliary drives independently adjust the final output speed, separating the functions of ratio determination and speed control.
Solution Approach 2:
The planetary gear set serves multiple functions: it provides a constant transmission ratio, reduces the speed range required from auxiliary drives, and enables compact design. The auxiliary drives simultaneously provide speed control and can operate independently for emergency operation.
2Adaptability or versatility
If the diameter of spur gears is adapted to specific application requirements, then the desired gear ratios can be achieved, but investment costs increase significantly
Solution Approach 1:
The system segments gear ratio determination (planetary set, fixed ratio) from speed control (auxiliary drives, variable speed). This allows using standard planetary gear sets with fixed ratios while achieving application-specific performance through auxiliary drive selection.
Solution Approach 2:
The auxiliary drives use smaller, less expensive spur gears compared to a fully customized planetary gear set. The auxiliary drives can be replaced or adjusted more economically than redesigning the entire planetary gear system for different applications.
3Adaptability or versatility
If a gear chain with stepped intermediate gear is used for auxiliary drives, then center distances and gear diameters can remain constant, but the gear chain structure becomes more complex
Solution Approach 1:
The stepped intermediate gear acts as an intermediary that enables multiple transmission ratios through different engagement positions. It mediates between the auxiliary drive and the planetary gear set, allowing ratio changes without altering center distances or requiring complex variable geometry mechanisms.
4Reliability
If the main drive motor is operated without load during startup using auxiliary drive speed imposition, then the motor can start without excessive load, but the startup control mechanism becomes more complex
Solution Approach 1:
The auxiliary drives automatically provide speed imposition during motor startup without requiring external control systems. The mechanical coupling through the planetary gear set and auxiliary drives enables the motor to be brought up to speed under light load conditions naturally, eliminating the need for complex electronic soft-start controls.
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
This design simplifies the structural design and manufacturing of drive devices, allows cost-effective implementation with reduced investment costs, and provides flexible speed control and emergency operation capabilities, suitable for high-speed applications with minimal space requirements.
Implementation Method 1
each made via a gear chain with a stepped intermediate gear
Implementation Method 2
the drive connections of the auxiliary drives are each made via a gear chain with a stepped intermediate gear
Implementation Method 3
the planetary gear set comprises a ring gear, a sun gear, a planet carrier and several planet gears
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a drive device which comprises a speed modulation gearbox (18) having a planetary gearbox (6), a main drive machine (1), connected to an input shaft (4) of the speed modulation gearbox, two auxiliary drives (3.1, 3.2), each connected to the planetary gearbox (6) via a drive connection, and an output shaft (11) of the speed modulation gearbox, which output shaft can be connected to a drive machine (2). The planetary gearbox (6) comprises a ring gear (6.1), a sun gear (6.2), a planet carrier (7) and a plurality of planet gears (6.3), the drive connections of the auxiliary drives (3.1, 3.2) being established by means of respective gear chains (9.1,10.1,9.2,10.2) having respective stepped idler gears (10.1, 10.2).