3D-Printed Flex Coupling for Rotary Encoder Torque Transmission
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Solution Overview
Problem
Existing flex couplings for rotary encoders in reduction gears are complex and costly due to their multi-part assembly, requiring extensive manufacturing and storage of individual components.
Innovation Solution
An additively manufactured flex coupling comprising a sleeve, spline, and reinforcement, which can be designed with helical structures and ribs for simplified production and assembly, reducing the need for multiple parts and supporting structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multi-part assembly is used for flexible coupling, then torque transmission and flexibility are achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple separate components (sleeve, bellows coupling, splined connection, stiffening elements) into a single integrated additively manufactured part. This merging eliminates the need for welding, pinning, gluing, and clamping operations, directly resolving the contradiction by simplifying manufacturing while maintaining the functional complexity of the original multi-part assembly
Solution Approach 2:
The single flexible coupling component performs multiple functions simultaneously: it provides torque transmission through the splined connection, maintains flexibility through the bellows structure, provides structural support through stiffening elements, and enables seal support through the hard-anodized outer surface. This multi-functionality in a single part resolves the contradiction by eliminating the need for multiple specialized components
2Reliability
If multiple individual components are manufactured and assembled, then functional requirements are met, but production cost and inventory requirements increase
Solution Approach 1:
By merging all functional components into a single additively manufactured part, the patent eliminates the need to manufacture, store, and assemble multiple individual components. This directly reduces production cost and inventory requirements while maintaining all necessary functional performance through the integrated design
Solution Approach 2:
The patent utilizes additive manufacturing technology to create complex geometries (helical stiffening elements, splined connections, bellows structures) that would be difficult or impossible to produce with traditional manufacturing methods. This parameter change in manufacturing technology enables cost-effective production of the integrated component while maintaining high functional performance
3Manufacturing precision
If complex assembly processes are used, then precise connections are achieved, but manufacturing time and labor requirements increase
Solution Approach 1:
The patent merges all connection features (splined connections, mounting interfaces, stiffening elements) into a single monolithic component manufactured in one additive printing process. This eliminates multiple assembly steps and precision alignment operations, directly improving manufacturing efficiency while maintaining connection precision through the inherent accuracy of additive manufacturing
Solution Approach 2:
The additive manufacturing process creates all connection features and structural elements in their final positions during the single manufacturing operation, eliminating the need for subsequent assembly and alignment operations. This preliminary action of creating all features in-place resolves the contradiction by maintaining precision while dramatically improving productivity
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 solution enables cost-effective and efficient production of a torsionally stiff and flexible coupling, reducing manufacturing and assembly costs while maintaining torque transmission capabilities.
Implementation Method 1
The flexible coupling ensures the transmission of the rotary signal between the gearbox interior and an external sensor
Implementation Method 2
Part of the shaft or the flexible coupling is designed to be flexible to facilitate installation and to compensate for slight axial misalignment of the sensor shaft
Data Source
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AI summary
The invention relates to an additively manufactured flexible coupling for the rotary angle encoder of a reduction gear and a rotary angle encoder as well as a reduction gear with at least one corresponding flexible coupling.