Grundfos Challenge

grabcad

The task at hand involves designing and developing a gear unit for a hydronic valve, one that incorporates a sophisticated compound planetary gear setup. This design boasts almost zero backlash, which translates to minimal efficiency losses of less than 15%. Furthermore, the gear unit is engineered to exhibit very low friction and near-zero maintenance requirements over its operational lifespan. The enclosure design prioritizes ease of mold release, eliminating thin-walled protrusions or supports that could compromise its structural integrity. To ensure a secure fit, studs have been strategically added to the front of the enclosure, which embed into the red housing. This setup enables the full torque to be effectively carried by the enclosure itself. For assembly purposes, the design facilitates an easy bottom-up approach, starting with the motor and adding subsequent layers in a logical sequence. The compound gear set has a ratio of 452:1, while the spur gears have a ratio of 2:1. When combined, these ratios result in a total gear ratio of 954:1. Additional documentation will be provided soon to further elaborate on this design.