Asymmetric Rotary Coupling for Misaligned Axis Assembly
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Solution Overview
Problem
Existing couplings for interconnecting items require precise alignment of the male and female parts, which can make assembly difficult and time-consuming, especially when the axes of rotation are misaligned.
Innovation Solution
The coupling design features a tap with a distal end that is longer on one side of the axis of rotation than the other, allowing for misalignment between the female and male parts. This design includes a projection on the female part and a flange on the male part that can engage without requiring exact alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the male and female parts require precise alignment of axes of rotation, then the coupling provides secure connection, but the assembly becomes difficult and time-consuming
Solution Approach 1:
The distal end of the tap is made asymmetric by extending it longer on one side of the second axis of rotation than on the opposite side. This asymmetric design allows the male and female parts to connect even when their axes of rotation are misaligned, eliminating the need for precise alignment while maintaining connection security.
2Strength
If the axes of rotation must coincide for proper engagement, then the coupling provides reliable torque transmission, but the assembly process becomes complex
Solution Approach 1:
The asymmetric distal end of the tap accommodates misaligned axes of rotation during assembly, while the groove and flange with end stop ensure proper engagement for torque transmission. This resolves the contradiction by allowing axis misalignment during assembly while maintaining strength during operation.
Solution Approach 2:
The groove and flange are pre-configured to guide the male part into proper engagement position as it is inserted into the female part. The end stop on the flange preliminarily determines the final engagement position, ensuring reliable torque transmission without requiring precise initial alignment.
3Stability of the object's composition
If the flange extends completely around the circular cylindrical proximal end, then the coupling provides maximum engagement stability, but the assembly becomes more difficult
Solution Approach 1:
The flange extends only partially (half way or less than half way) around the circular cylindrical proximal end rather than completely around it. This localized flange configuration provides sufficient engagement stability for the application while reducing assembly difficulty by allowing easier insertion and manipulation of the male part into the female part.
Data Source
AI summary
A coupling including a female part attached to one of two items, and a male part attached to the other. The female part has a projection extending only on one side of a plane parallel to a first axis of rotation and away from the end of a circular cylindrical hole and forming a segment of an inner surface. The tap of the male part includes a circular cylindrical proximal end. A groove is arranged in one, and a flange is arranged on the other one of the circular cylindrical inner surface and the proximal end, and the flange and groove are adapted such that the flange can slide in the groove about the first axis of rotation, when the tap is rotated in the hole. The distal end of the tap, in the direction along a second axis of rotation, is longer on one side of the second axis of rotation than on the opposite side.