Sprocket Surface Texturing for Noise Reduction
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Solution Overview
Problem
People conveyors, such as moving walkways and escalators, experience noise and vibration due to air entrapment and particulate accumulation between the sprocket and belt, leading to increased maintenance costs and reduced ride comfort.
Innovation Solution
Incorporating a hierarchical texturing, such as a superimposed bi-direction chevron pattern, on the sprocket surface to facilitate air exit and reduce particulate adherence, along with a debris escape channel and a sweeper brush for cleaning, and applying a diamond-like carbon or nano-composite coating for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a toothed sprocket and belt system is used to drive conveyance elements, then positive driving and slipless operation are achieved, but noise and vibration increase due to air entrapment and rapid expulsion from meshing cavities
Solution Approach 1:
The patent extracts and removes trapped air from the meshing cavity between sprocket teeth and belt teeth by providing escape channels that allow air to exit gradually rather than being rapidly expelled, thereby reducing noise while maintaining positive driving engagement
Solution Approach 2:
The patent introduces an intermediary air escape channel between the meshing teeth that mediates the air pressure buildup, allowing controlled air release that prevents the harmful rapid expulsion effect while preserving the driving engagement
2Reliability
If a toothed sprocket and belt system is used to drive conveyance elements, then positive driving is achieved, but vibration increases due to air entrapment and rapid expulsion
Solution Approach 1:
The patent extracts trapped air from the meshing cavity through dedicated escape channels, removing the source of vibration caused by rapid air expulsion while maintaining the positive driving engagement between teeth
Solution Approach 2:
The air escape channel acts as an intermediary that mediates air pressure changes during meshing, providing a controlled release path that prevents sudden pressure changes and associated vibrations
3Reliability
If dust particles attach to sprocket and belt surfaces through electrostatic and Van der Waals forces, then wear and deterioration increase, but maintenance costs and operation costs increase
Solution Approach 1:
The patent incorporates a sweeper brush that automatically contacts and cleans the engagement surface of sprocket teeth during operation, providing self-service maintenance that removes dust particles before they cause wear, thereby reducing maintenance costs while preserving meshing conditions
Solution Approach 2:
The sweeper brush performs preliminary cleaning action on the engagement surfaces before dust particles can cause significant wear and deterioration, preventing the problem rather than addressing it after damage occurs
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 solution effectively reduces noise and vibration, improves durability, and lowers maintenance costs by addressing air entrapment and particulate issues, resulting in improved reliability and ride comfort for people conveyors.
Implementation Method 1
applying a diamond-like carbon or nano-composite coating for enhanced performance
Implementation Method 2
applying a diamond-like carbon or nano-composite coating for enhanced performance
Implementation Method 3
dust particles can attach to surfaces of the sprocket and/or surfaces of the belt/chain through electrostatic and Van der Waals forces
Implementation Method 4
dust particles can attach to surfaces of the sprocket and/or surfaces of the belt/chain through electrostatic and Van der Waals forces
Implementation Method 5
an abnormal noise may be induced when the belt/chain of the drive element engages with or disengages from the sprocket. Such noise may be generated by air that is trapped between the belt/chain and the sprocket which is rapidly expelled from a cavity that exists between the belt/chain and the sprocket
Data Source
AI summary
People conveyors and components for people conveyors are described. The components include a toothed surface having at least one tooth. The at least one tooth having an engagement surface and a surface pattern comprising pattern channels formed into the engagement surface.