V-pulley with Segmented Gears and Friction Grooves
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Solution Overview
Problem
Existing V-pulleys experience slippage, wear, and short service life due to low strength and high manufacturing costs, especially under high power and heavy load conditions, with complex mold designs increasing production expenses.
Innovation Solution
A V-pulley design featuring a pulley body with coaxial annular gears and inner wheels, where the outer wheels, gears, and inner wheels are connected through a specific structure that includes meshing teeth and inclined friction surfaces, reducing slippage and wear, and allowing for separate manufacturing to avoid stress concentration and complex mold requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If convex-concave teeth are cast in the belt groove of the pulley body using aluminum material, then the pulley can achieve mesh transmission, but the convex-concave teeth wear easily and have low strength
Solution Approach 1:
The pulley is divided into multiple independent components: pulley body, wheels, and gears. The gears with meshing teeth are separate from the pulley body and wheels, allowing each component to be optimized independently. This segmentation enables the use of more durable materials and manufacturing processes for the meshing teeth while maintaining the overall pulley structure.
Solution Approach 2:
The invention uses composite construction by combining different materials for different components. The pulley body and wheels can be made from one material while the gears are made from another material better suited for meshing teeth. This allows optimization of each component's material properties for its specific function, improving overall durability and strength.
2Device complexity
If the pulley body and convex-concave teeth are cast integrally, then the structure is simple, but complex molds are required and manufacturing cost is greatly increased
Solution Approach 1:
The pulley system is segmented into separately manufacturable components (pulley body, wheels, gears) that can be produced using standard manufacturing processes without requiring complex integrated molds. These components are then assembled together, reducing mold complexity while maintaining structural integrity.
Solution Approach 2:
Multiple separately manufactured components (pulley body, wheels, gears) are combined through assembly to form the complete pulley system. This merging approach allows each component to be manufactured using simpler, more cost-effective processes while achieving the same functional result as an integral structure.
3Productivity
If a smaller driving pulley drives a larger driven pulley, then the transmission ratio is achieved, but slippage phenomenon occurs between the belt and the smaller pulley
Solution Approach 1:
The invention introduces gears with meshing teeth as an intermediary mechanism between the belt and the pulley system. The belt drives the gear through meshing teeth rather than relying solely on friction, providing positive engagement that prevents slippage while maintaining the desired transmission ratio.
4Device complexity
If the wheels are integrally formed with the pulley body, then the structure is simple, but stress concentration occurs at connection positions
Solution Approach 1:
The wheels are separated from the pulley body as independent components rather than being integrally formed. This segmentation eliminates stress concentration at connection positions by removing the need for connections, while the wheels are secured to the pulley body through mounting structures that distribute loads more evenly.
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 V-pulley achieves reduced slippage, increased service life, and lower manufacturing costs by utilizing a combined friction and mesh transmission mechanism, ensuring stability and reliability under high power and heavy load conditions.
Implementation Method 1
The outer circumferential surfaces of the gears are provided with meshing teeth disposed at an interval in a convex-concave manner... a combined transmission manner of friction transmission of the belt groove side surfaces and mesh transmission of the meshing teeth is implemented
Implementation Method 2
a combined transmission manner of friction transmission of the belt groove side surfaces and mesh transmission of the meshing teeth is implemented... The opposite end surfaces of the two adjacent wheels form friction transmission belt groove side surfaces
Data Source
AI summary
A V-pulley includes a pulley body having a through hole provided at the center. Wheels are connected on the pulley body. An outer wheel is provided at each of two ends of the pulley body. Coaxial annular gears and annular inner wheels are alternately arranged between the two outer wheels. The diameter of a gear is less than that of an inner wheel. The outer wheels, the gears, and the inner wheels are fixedly connected through a connecting structure. The outer circumferential surfaces of the gears have meshing teeth disposed at an interval in a convex-concave manner. Two adjacent wheels and a gear between them form a V-belt groove. The opposite end surfaces of the two adjacent wheels form friction transmission belt groove side surfaces. The gear between the two adjacent wheels forms a mesh transmission gear. The belt groove side surfaces are inclined smooth surfaces.