Water Jet Multi-Disc Sprockets for Precise Belt Tracking
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Solution Overview
Problem
Existing methods for manufacturing larger width sprockets, such as die casting and sand casting, face challenges in ejecting the sprocket from the mold without creating a drafting angle, which affects belt tracking, and are also expensive and time-consuming.
Innovation Solution
The use of a water jet cutter to form multi-disc sprockets, which are coaxially aligned and secured together, allowing for the creation of radially outwardly extending teeth without thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die casting method is used to manufacture sprockets, then precise tooth profiles can be formed, but drafting angles are created in the tooth profile when ejecting from the mold, which causes belt tracking issues
Solution Approach 1:
The sprocket is divided into multiple thin disc components that are stacked coaxially to form the complete sprocket. Each disc is manufactured separately using water jet cutting, avoiding the mold ejection problem entirely. The segmentation allows precise tooth profiles to be created without drafting angles while maintaining reliability through proper axial alignment of multiple discs.
Solution Approach 2:
The traditional mechanical die casting process is replaced with water jet cutting technology. This substitution eliminates the need for mold ejection and associated drafting angles, while the water jet process can create precise tooth profiles through computer-controlled cutting paths, thereby resolving the contradiction between precision and reliability.
2Reliability
If sand casting technique is used to manufacture larger width sprockets, then the sprocket can be formed without drafting angle issues, but the tooth profile must be created through expensive and time-consuming machining techniques
Solution Approach 1:
Traditional machining techniques (CNC, tooth shaping, tooth hobbing) are replaced with water jet cutting technology. The water jet process directly cuts the tooth profiles into the disc components during manufacturing, eliminating the need for subsequent expensive and time-consuming machining operations, thereby significantly improving productivity while maintaining reliable tooth profiles.
Solution Approach 2:
The tooth profiles are formed during the initial disc manufacturing process rather than as a separate subsequent operation. By preliminary cutting the tooth profiles into the disc components using water jet technology, the need for additional machining steps is eliminated, improving manufacturing efficiency without compromising tooth profile quality or belt tracking reliability.
3Length of stationary object
If traditional machining techniques are used to create tooth profiles in blank sprockets, then large width sprockets can be manufactured, but the process is expensive and time consuming
Solution Approach 1:
Traditional sequential machining operations are replaced with water jet cutting technology that can directly manufacture complete disc components with tooth profiles in a single process. This substitution dramatically reduces manufacturing time while enabling the production of large width sprockets by stacking multiple thin discs, effectively resolving the contradiction between sprocket width capability and manufacturing time.
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 method enables the efficient and cost-effective production of larger width sprockets with precise tooth profiles and no thermal stress, improving belt tracking and reducing manufacturing time and costs.
Implementation Method 1
Each of the plurality of individual disc sprockets is formed by cutting a metal plate with a water jet cutter
Data Source
AI summary
Methods of making a sprocket, including a multi-disc sprocket formed by assembling multiple disc sprockets. The methods including using a water jet cutter, optionally with abrasive, to form the disc sprocket. The resulting disc sprocket can have radially outwardly extending teeth. No thermal stress is evident within the sprocket or the disc sprocket, including proximate the teeth.