Stacked Disc Sprocket Assembly for Wide Precise Tooth Profiles
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Solution Overview
Problem
Current manufacturing methods for larger width sprockets are limited by the difficulty in forming precise tooth profiles without creating drafting angles, leading to increased costs and inefficiencies, particularly in die cast and sand casting techniques.
Innovation Solution
A multi-disc sprocket system comprising coaxially aligned disc sprockets with identical outer diameters and tooth profiles, secured by fasteners and end flanges, allowing for flexible axial width adjustment and hub-less construction, enabling efficient and cost-effective production using stamping techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die cast method is used to manufacture sprockets, then precise tooth profiles can be formed, but drafting angles are created in the tooth profile when sprocket width increases
Solution Approach 1:
The sprocket is divided into multiple thin disc-shaped elements stacked coaxially to achieve the desired width. Each disc is stamped separately using a flat stamping process that does not create drafting angles, then the discs are assembled together with fasteners to form the complete sprocket. This segmentation allows precise tooth profiles to be maintained while achieving large overall width.
2Ease of manufacture
If sand casting technique is used for larger width sprockets, then drafting angle issues are avoided, but tooth profile precision and production cost are compromised
Solution Approach 1:
Instead of casting the entire large-width sprocket as a single piece, the invention segments it into multiple thin discs that are each stamped with precise tooth profiles. This avoids the imprecision of sand casting while maintaining manufacturability for large widths through assembly of multiple components.
Solution Approach 2:
The invention replaces the sand casting mechanical process with a stamping and assembly process. Stamping provides precise tooth profiles through die-forming, while assembly of multiple discs achieves the required width, substituting the casting mechanism with a combination of forming and fastening operations.
3Device complexity
If traditional single-piece sprocket construction is used, then structural simplicity is maintained, but axial width adjustment flexibility is limited
Solution Approach 1:
The sprocket is constructed from multiple stackable disc elements that can be varied in number to achieve different axial widths. This modular segmentation provides flexibility in width adjustment while maintaining relatively simple individual disc structures and assembly procedures through coaxial stacking and fastening.
Solution Approach 2:
The sprocket design allows dynamic adjustment of axial width by varying the number of disc elements in the stack. This enables the same basic disc design to be adapted for different width requirements, providing versatility while keeping each individual disc structurally simple.
Data Source
AI summary
A sprocket system including a sprocket assembled from multiple disc sprockets coaxially aligned and secured together to provide a desired axial width for the sprocket is described. In some embodiments, the sprocket described herein is a hub-less sprocket.