A solid-state modular coupler

Abstract

This invention belongs to the field of mechanical transmission technology and discloses a solid-state modular coupler, including a driving end and a driven flange arranged coaxially. The driving end includes a rotor assembly, a housing, a first end cover, and a second end cover. The rotor assembly includes a rotor body, a guide sleeve, a hydraulic damping rod, a friction module, and a tension spring. The outer wall of the rotor body has a raised edge, and the guide sleeve is annularly mounted on the raised edge. A transmission component is slidably installed inside the guide sleeve. The housing is fitted outside the transmission component, and its inner wall has a friction material layer. Both ends of the housing are mounted on the rotor body via bearings. A torque transmitter is connected to one side of the housing, and the driven flange is fitted inside the torque transmitter. A safety pin is installed between the two. The transmission component of this invention has good structural strength and impact resistance, and combined with hydraulic damping, it achieves smooth soft start, with advantages such as high transmission efficiency, reliable overload protection, and convenient maintenance.

Description

Technical Field

[0001] This invention belongs to the field of mechanical transmission technology, and specifically relates to a solid-state modular coupler. Background Technology

[0002] In industries such as mining, metallurgy, and power, large equipment like belt conveyors and scraper conveyors are typically driven by electric motors. To reduce starting impact, lower starting current, and provide overload protection, a coupling is required between the motor and the driven machine. Currently, torque-limiting hydraulic couplings are widely used, but they suffer from drawbacks such as low transmission efficiency (typically a maximum of 95%), high energy consumption, frequent maintenance, and non-adjustable starting characteristics. While some mechanical couplings can achieve soft starts, their complex structure, insufficient overload protection reliability, and the need to move the motor or driven machine when replacing the safety pin result in long maintenance times and reduced production efficiency. Summary of the Invention

[0003] The purpose of this invention is to solve the problems in the background technology and provide a solid modular coupler that solves the problems of low transmission efficiency, large starting impact, poor overload protection reliability, and inconvenient replacement of safety pins in existing torque-limiting hydraulic couplers. It features high-efficiency transmission, smooth and controllable soft start, reliable overload protection, and convenient maintenance.

[0004] The objective of this invention is achieved through the following technical solution: A solid-state modular coupler includes a driving end and a driven flange coaxially arranged. The driving end includes a rotor assembly, a housing, a first end cover, and a second end cover. The rotor assembly includes a rotor body, guide sleeves, a transmission assembly, a hydraulic damping rod, and a tension spring. A raised edge is machined on the outer wall of the rotor body. Several guide sleeves are uniformly mounted annularly on the raised edge. A transmission assembly is slidably installed inside each guide sleeve. The transmission assembly includes a support column slidably installed inside the guide sleeve and a friction slider fixedly connected to one end of the support column. The hydraulic damping rod and the tension spring are both installed at the inner ends of the support column and the guide sleeve. Between the surfaces, the housing is fitted onto the outside of several friction sliders. A layer of friction material is provided on the inner wall of the housing. The annular surface of the friction slider near the housing is an arc surface that matches the contour of the inner wall of the housing. A first end cover and a second end cover are respectively connected to both ends of the housing. The first end cover and the second end cover are rotatably mounted on the rotor body on both sides of the flange via bearings. An annular baffle is installed on the side of the first end cover and the second end cover away from the flange to block the bearing. An annular torque transmitter is connected to the side of the housing away from the rotor body. The driven flange is fitted inside the torque transmitter. Multiple safety pins are evenly installed between the driven flange and the torque transmitter.

[0005] The support column has support ribs machined on both sides along the rotation direction, and the inner wall of the guide sleeve is clearance-fitted with the outline of the support column.

[0006] The number of guide sleeves is six, and the six guide sleeves are distributed around the circumference of the convex edge.

[0007] The number of safety pins is four, and the driven flange and the torque transmitter are machined with an installation port that matches the contour of the safety pins.

[0008] A brake wheel or brake disc is installed on the driven flange.

[0009] The beneficial effects of the solid-state modular coupler provided by this invention are: (1) Through the synergistic effect of hydraulic damping rod and tension spring, the contact speed between friction slider and inner wall of housing under centrifugal force is controlled by damping, so as to realize the adjustable and controllable start-up time and start-up speed, avoid start-up impact, and at the same time, the heavy load start-up of motor can be converted into no-load start-up, which can effectively reduce start-up energy consumption. (2) During normal operation, there is no speed difference and no friction loss between the driving end and the driven flange, and the transmission efficiency can reach more than 99%, which is higher than that of the torque-limiting hydraulic coupling. (3) A safety pin is used as an overload protection element. When the load exceeds the rated value, the safety pin is sheared and the driving end and the driven end are separated. At the same time, if the safety pin is not sheared, the rotor assembly can slip to avoid stalling. The friction heat can help soften and shear the safety pin, forming a double protection. (4) When the safety pin is cut off, it is only necessary to remove the fixing bolts of the torque transmitter and move it along the circumference of the torque transmitter to expose the broken safety pin for replacement. There is no need to move the motor or working unit, which can greatly shorten the maintenance time. (5) The support ribs set on both sides of the rotation direction of the support column increase the cross-sectional area of ​​the support column, effectively improving the bending strength and shear resistance of the support column when subjected to centrifugal force, friction force and radial impact load; at the same time, the support ribs and the inner wall of the guide sleeve form a multi-point support structure. Under the impact load generated when the friction slider contacts the inner wall of the housing, the support ribs can evenly transmit the impact force to the guide sleeve, avoid stress concentration, significantly improve the overall structural strength and impact resistance of the friction slider, and effectively extend the service life of the transmission device. (6) The smoothness of the sliding process is ensured by the clearance fit between the support rib and the guide sleeve, while the circumferential rotation of the support column is effectively restricted, ensuring the stability of the friction slider. (7) The annular baffle effectively restricts the circumferential transmission of the bearing and improves the reliability of the entire equipment operation. Attached Figure Description

[0010] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0011] Figure 1 This is a structural schematic diagram provided for an embodiment of the present invention.

[0012] Figure 2 for Figure 1 Cross-sectional view of line A-A in the middle.

[0013] Figure 3 A cross-sectional view of the guide sleeve and support column provided in an embodiment of the present invention.

[0014] Figure 4 This is a schematic diagram of the active terminal provided in an embodiment of the present invention.

[0015] Figure 5 This is a schematic diagram of the structure of the hydraulic damping rod provided in an embodiment of the present invention.

[0016] Figure 6 This is a schematic diagram of the installation of the driven flange and torque transmitter provided in an embodiment of the present invention.

[0017] Figure 7 A coupler with a brake wheel installed is provided in an embodiment of the present invention.

[0018] Figure 8 A coupler with a brake disc installed is provided for an embodiment of the present invention.

[0019] The markings in the diagram are: 1. Rotor body; 101. Lug; 2. Guide sleeve; 3. Transmission assembly; 301. Support column; 302. Friction slider; 303. Support rib; 4. Hydraulic damping rod; 5. Tension spring; 6. Housing; 601. Friction material layer; 7. First end cover; 8. Second end cover; 9. Bearing; 901. Annular baffle; 10. Torque transmitter; 11. Driven flange; 12. Safety pin; 13. Brake wheel; 14. Brake disc. Detailed Implementation

[0020] Example 1

[0021] like Figures 1-6 As shown, the solid-state modular coupler provided in this embodiment includes an active end and a driven flange 11 arranged coaxially.

[0022] like Figure 4 As shown, the active end includes a rotor assembly, a housing 6, a first end cover 7, and a second end cover 8.

[0023] like Figure 2 As shown, the rotor assembly includes a rotor body 1, a guide sleeve 2, a transmission assembly 3, a hydraulic damping rod 4, and a tension spring 5.

[0024] like Figure 1 , Figure 2 As shown, a raised edge 101 is machined on the outer wall of the rotor body 1. The raised edge 101 serves as the mounting base for the entire transmission assembly 3, ensuring the radial positioning accuracy and circumferential uniformity of each transmission assembly 3. Several guide sleeves 2 are uniformly installed in a ring on the raised edge 101. In this embodiment, there are six guide sleeves 2. The uniform ring distribution of the guide sleeves 2 ensures that the centrifugal force is evenly distributed, ensuring that the contact pressure between the friction slider 302 and the inner wall of the housing 6 is consistent along the circumference during startup, avoiding uneven wear, and improving the stability and service life of the whole machine.

[0025] like Figure 2 As shown, a transmission assembly 3 is slidably installed inside each guide sleeve 2. The transmission assembly 3 includes a support column 301 slidably installed inside the guide sleeve 2 and a friction slider 302 fixedly connected to one end of the support column 301. Figure 3 As shown, the support column 301 has support ribs 303 machined on both sides along the rotation direction. The inner wall of the guide sleeve 2 is clearance-fitted with the contour of the support column 301. The support ribs 303 and the inner wall of the guide sleeve 2 form line contact or narrow surface contact. While ensuring smooth radial sliding of the support column 301, it can also limit the friction slider 302 to ensure the stability of the friction slider 302's posture and avoid poor contact or local wear caused by the friction slider 302's slippage. In addition, the support ribs 303 significantly increase the cross-sectional area of ​​the support column 301, greatly improving its bending strength and shear resistance. At the moment of coupling start-up, when the friction slider 302 is in contact with the inner wall of the housing 6, a large impact load will be generated. This impact force is transmitted to the guide sleeve 2 through the support column 301. The presence of the support ribs 303 changes the stress-bearing cross section of the support column 301 from a simple rectangle or circle to an irregular cross section with reinforcing ribs, effectively dispersing the impact load to a larger bearing area, avoiding stress concentration, and significantly improving the impact resistance and fatigue life of the transmission component 3. Tests showed that the transmission component 3 with supporting ribs 303 has an impact resistance of about 40% higher than that without ribs under the same working conditions, effectively solving the technical problem that the supporting components in traditional friction couplings are prone to bending, deformation or breakage.

[0026] The hydraulic damping rod 4 and the tension spring 5 are both installed between the inner end faces of the support column 301 and the guide sleeve 2. The piston rod of the hydraulic damping rod 4 extends from the middle of the tension spring 5 and is threadedly connected to the end of the support column 301. The hydraulic damping rod 4, in conjunction with the guide sleeve 2 and the support column 301, ensures that the centrifugal force, damping force, and tension spring 5 are transmitted along the same straight line. The hydraulic damping rod 4 and the tension spring 5 work together: as... Figure 5 As shown, the hydraulic damping rod 4 provides damping force to control the radial movement speed of the transmission component 3, causing the friction slider 302 to move slowly outward under the action of centrifugal force. This avoids the impact and noise caused by the violent contact between the friction slider 302 and the inner wall of the housing 6 at the moment of contact, and realizes the adjustable and controllable start-up time. During use, the soft start time can be flexibly adjusted according to different working conditions by replacing the hydraulic damping rod 4 with different damping characteristics (such as changing the viscosity of the damping medium or the throttling orifice diameter), which significantly improves the adaptability of the equipment to different load characteristics. The tension spring 5 provides the radial restoring force of the friction slider 302, ensuring that the friction slider 302 separates from the inner wall of the housing 6 when the machine stops or at low speed, avoiding frictional loss of the friction slider 302 when it is not in operation.

[0027] like Figure 1 , Figure 2 As shown, the housing 6 is fitted onto the outer side of the working surface of the six friction sliders 302. A friction material layer 601 is provided on the inner wall of the housing 6. The friction material layer 601 is selected from existing friction materials according to the working conditions. The selection of the friction material layer 601 is something that should be known to those skilled in the art. The annular surface of the friction slider 302 near the housing 6 is an arc surface that matches the contour of the inner wall of the housing 6. This arc surface structure increases the contact area between the friction slider 302 and the inner wall of the housing 6, and at the same time makes the contact pressure distribution more uniform. Under the same centrifugal force conditions, it can generate greater friction force, thereby improving the torque transmission capability. At the same time, the arc surface design reduces the concentration of contact stress, reduces the local wear of the friction material layer 601, and extends the service life of the friction material. The friction material layer 601 and the arc surface of the friction slider 302 cooperate to form a friction pair. The housing 6 is connected to a first end cover 7 and a second end cover 8 at both ends. The first end cover 7 and the second end cover 8 are rotatably mounted on the rotor body 1 on both sides of the flange 101 via bearings 9. The bearing 9 support structure forms a rotational support relationship between the housing 6 and the rotor assembly, which not only ensures that the housing 6 can rotate with the rotor assembly, but also ensures the coaxiality between the housing 6 and the rotor assembly, reducing vibration and noise during operation.

[0028] An annular baffle 901 is installed on the side of the first end cover 7 and the second end cover 8 away from the raised edge 101 to block the bearing 9. The annular baffle 901 effectively restricts the axial movement of the bearing 9, prevents the bearing 9 from shifting when rotating at high speed or subjected to axial impact, ensures the positioning accuracy and operational reliability of the bearing 9, and extends the service life of the bearing 9. At the same time, the mating structure of the annular baffle 901 and the end cover forms a closed bearing 9 cavity, which is convenient for filling with grease, and achieves good lubrication and dustproof sealing of the bearing 9.

[0029] like Figure 4As shown, the housing 6 is connected to an annular torque transmitter 10 on the side away from the rotor body 1. The torque transmitter 10 serves as an intermediate component connecting the housing 6 and the driven flange 11. Its annular structure ensures the uniformity and coaxiality of torque transmission.

[0030] like Figure 6 As shown, the driven flange 11 is fitted inside the torque transmitter 10, with a gap between the driven flange 11 and the torque transmitter 10 for easy installation and disassembly. Multiple safety pins 12 are evenly installed between the driven flange 11 and the torque transmitter 10. In this embodiment, there are four safety pins 12, evenly distributed along the circumference. As overload protection elements, the number and arrangement of the safety pins 12 ensure that the rated torque can be evenly transmitted under normal operating conditions, preventing individual safety pins 12 from bearing excessive loads. When an overload occurs, the safety pin 12 is sheared, and the active end quickly separates from the driven flange 11, cutting off power transmission and effectively protecting the motor, driven machine, and coupler body from damage. When the load on the safety pin 12 exceeds the rated value but does not reach the instantaneous shearing threshold of the safety pin 12, the rotor assembly can slip, preventing motor stall. As friction generates heat, the temperature rises to the softening temperature of the safety pin 12 material, causing the safety pin 12 to weaken and shear, achieving dual overload protection and effectively improving equipment safety. Once the safety pin 12 is sheared, the operator only needs to remove the fastening bolts of the torque transmitter 10 and move the torque transmitter 10 axially to expose the broken safety pin 12 for cleaning and replacement. The core of this structural design is that the bolted connection between the torque transmitter 10 and the housing 6 can be completely disassembled without affecting the tightness of the housing 6 and the end cover. Furthermore, the gap between the driven flange 11 and the torque transmitter 10 provides space for axial movement. The entire maintenance process does not require moving the motor or work unit and can be completed quickly by a single operator, significantly reducing equipment downtime and improving production efficiency.

[0031] Through the synergistic effect of the above structures, the solid-state modular coupler disclosed in this invention achieves smooth and controllable soft starting during motor startup, reducing starting current by approximately 65% ​​and significantly reducing starting energy consumption. During normal operation, there is no speed difference or friction loss between the driving and driven ends, and the transmission efficiency can reach over 99%. Overload protection is reliably achieved through the shearing action of safety pin 12. Maintenance requires no relocation of the unit, making operation convenient. The entire unit has a compact structure, stable operation, and long service life, and can be widely used in large equipment such as belt conveyors and scraper conveyors in industries such as mining, metallurgy, and power.

[0032] The working process of this invention is as follows: The motor drives the rotor body 1 to rotate, causing the entire rotor assembly to rotate. The transmission component 3, under centrifugal force, tends to move radially outward. The hydraulic damping rod 4 provides damping force, suppressing the radial movement speed of the transmission component 3, causing the friction slider 302 to move slowly outward. As the rotational speed increases, the centrifugal force gradually increases. When the centrifugal force exceeds the sum of the tension of the tension spring 5 and the damping force of the hydraulic damping rod 4, the friction slider 302 comes into contact with the friction material layer 601 on the inner wall of the housing 6.

[0033] After bonding, as the rotation speed increases further, the bonding pressure and friction increase, causing the housing 6 to rotate. The rotation of the housing 6 is transmitted to the driven flange 11 through the torque transmitter 10 and the safety pin 12, ultimately driving the working machine to operate. By adjusting the damping characteristics of the hydraulic damping rod 4 (such as the viscosity of the damping medium, the throttling orifice diameter, etc.), the start-up time can be adjusted and controlled.

[0034] When the load exceeds the rated value, the safety pin 12 is sheared, separating the driving end from the driven flange 11, protecting the motor, the driven machine, and the coupler body. If the safety pin 12 is not sheared, the rotor assembly slips, and the motor does not stall. When frictional heat raises the temperature to the softening temperature of the safety pin 12 material, the safety pin 12 is sheared, achieving dual protection.

[0035] Once the safety pin 12 is sheared off, the operator only needs to remove the fastening bolts of the torque transmitter 10 and move the torque transmitter 10 axially to expose the broken safety pin 12 for cleaning and replacement. This process does not require moving the motor or machine unit, is convenient to operate, and allows for quick resumption of production.

[0036] Example 2

[0037] This embodiment optimizes the structure of the driven flange 11 based on embodiment 1 to adapt to working conditions requiring automatic functions, such as... Figure 7 As shown, a brake wheel 13 is fixedly connected to the driven flange 11. The driving wheel is located on the outer circumference of the driven flange 11, and its outer surface is a cylindrical braking surface, which is used to cooperate with an external brake (such as a holding brake) to brake the driven flange 11.

[0038] The braking surface of the brake wheel 13 is hardened or has a wear-resistant layer welded on, giving it high hardness and wear resistance, enabling it to withstand the frictional heat and wear generated during frequent braking. The introduction of the brake wheel 13 allows the coupler of this invention to not only have soft-start and overload protection functions, but also integrate braking functionality, making it particularly suitable for applications requiring frequent starts and stops or positioning, such as inclined belt conveyors, elevators, and hoisting machinery.

[0039] Example 3

[0040] This embodiment, based on embodiment 1, provides another way to implement the braking structure, such as... Figure 8 As shown, a brake disc 14 is fixedly connected to the driven flange 11. The brake disc 14 has a disc-shaped structure, with its two axial sides serving as braking working surfaces, used to cooperate with disc brakes (such as hydraulic disc brakes and pneumatic disc brakes) to achieve braking function.

[0041] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications and substitutions based on the technical solutions and inventive concepts provided by the present invention should be covered within the scope of protection of the present invention.

Claims

1. A solid-state modular coupler, comprising an active end and a driven flange (11) coaxially arranged, characterized in that: The active end includes a rotor assembly, a housing (6), a first end cover (7), and a second end cover (8). The rotor assembly includes a rotor body (1), a guide sleeve (2), a transmission assembly (3), a hydraulic damping rod (4), and a tension spring (5). A raised edge (101) is machined on the outer wall of the rotor body (1). Several guide sleeves (2) are evenly installed in a ring on the raised edge (101). A transmission assembly (3) is slidably installed in each guide sleeve (2). The transmission assembly (3) includes a support column (301) slidably installed in the guide sleeve (2) and a friction slider (302) fixedly connected to one end of the support column (301). Support ribs (303) are machined on both sides of the support column (301) along the rotation direction. The inner wall of the guide sleeve (2) is clearance-fitted with the contour of the support column (301). The hydraulic damping rod (4) and the tension spring (5) are both installed between the support column (301) and the guide sleeve (2). Between the inner end faces of the housing (6), the housing (6) is fitted on the outside of several friction sliders (302). A ring of friction material layer (601) is provided on the inner wall of the housing (6). The ring surface of the friction slider (302) near the housing (6) is an arc surface that matches the contour of the inner wall of the housing (6). The two ends of the housing (6) are respectively connected to the first end cover (7) and the second end cover (8). The first end cover (7) and the second end cover (8) are rotatably mounted on the rotor body (1) on both sides of the flange (101) through the bearing (9). The first end cover (7) and the second end cover (8) are installed on the side away from the flange (101) with an annular baffle (901) that blocks the bearing (9). The side of the housing (6) away from the rotor body (1) is connected to an annular torque transmitter (10). The driven flange (11) is fitted inside the torque transmitter (10). Multiple safety pins (12) are evenly installed between the driven flange (11) and the torque transmitter (10).

2. The solid-state modular coupler according to claim 1, characterized in that: The number of guide sleeves (2) is six, and the six guide sleeves (2) are distributed around the circumference of the convex edge (101).

3. The solid-state modular coupler according to claim 1, characterized in that: The number of safety pins (12) is four, and the driven flange (11) and the torque transmitter (10) are machined with mounting ports that are adapted to the contour of the safety pins (12).

4. The solid-state modular coupler according to claim 1, characterized in that: A brake wheel (13) or a brake disc (14) is installed on the driven flange (11).

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