Central-Element Universal Joint for High Torque at 45° Misalignment
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Solution Overview
Problem
Universal joints face challenges with bending loads, stress over time, and space limitations in high torque applications, particularly at angles greater than 35 degrees, leading to binding or interference issues and the need for additional joints to accommodate angular offset, which complicates assembly and limits load transmission.
Innovation Solution
A compact linkage system with a central element and dual head arms that allows for higher torque transmission over greater offset angles, featuring a C-shaped beak design with optimized dimensions and a retaining member system to prevent central element displacement, enabling smoother operation and rotation at misalignment angles up to 45 degrees.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional pin and yoke universal joints are used, then the structure is simple, but the torque transmission capability is limited and binding occurs at angles greater than 35 degrees
Solution Approach 1:
The universal joint is divided into a central element and a dual head arm assembly with separate bearing surfaces. The central element contains bearing surfaces that interface with bearing surfaces on the dual head arm, allowing independent optimization of each component's geometry to handle higher torques and larger offset angles without binding
Solution Approach 2:
The patent changes the geometric parameters of the bearing surfaces, specifically using convexly shaped bearing surfaces on the central element that complement concavely shaped bearing surfaces on the dual head arm. This geometric configuration allows operation at offset angles greater than 35 degrees while maintaining smooth motion transmission and accommodating higher torque loads
2Force
If larger universal joints are used for high torque applications, then torque transmission improves, but space limitations are exceeded
Solution Approach 1:
The central element is received within a cavity of the dual head arm assembly, with the central element nested between the two head portions. This nested configuration allows the high-torque-capable central element to be housed within a compact dual head arm structure, achieving high torque transmission without proportionally increasing the overall joint volume
Solution Approach 2:
The patent optimizes the three-dimensional geometry of the bearing surfaces and central element configuration to transmit torque more efficiently within a smaller volume. The convexly shaped bearing surfaces on the central element engage with concavely shaped surfaces on the dual head arm, creating a compact yet high-capacity torque transmission interface that fits within space-constrained applications
3Adaptability or versatility
If additional joints are used to accommodate angular offset, then the offset angle capability increases, but assembly complexity increases
Solution Approach 1:
The dual head arm assembly serves multiple functions simultaneously: it provides the universal joint connection, accommodates large offset angles through its geometry, and incorporates the central element retention mechanism. This multi-functional design eliminates the need for separate components to handle offset angles, simplifying the overall assembly while maintaining high adaptability
Solution Approach 2:
The patent merges the central element and dual head arm into a single integrated assembly where the central element is retained by the dual head arm through grooves and retaining members. This combined structure achieves greater offset angle capability than traditional single-joint designs without requiring multiple separate joints, thereby reducing assembly complexity
4Ease of manufacture
If the central element is not retained, then assembly is simpler, but the central element may displace causing failure
Solution Approach 1:
Retaining members act as intermediaries between the central element and the dual head arm assembly. These retaining members engage with grooves on the central element and are secured by the dual head arm, providing a simple yet effective retention mechanism that prevents displacement while maintaining assembly simplicity
Solution Approach 2:
The central element incorporates grooves that automatically engage with retaining members during assembly, and the dual head arm structure itself provides the retention mechanism through its geometry. This self-retaining design ensures the central element remains securely positioned without requiring complex external retention systems, balancing assembly simplicity with operational reliability
Data Source
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AI summary
A linkage system for transmitting torque includes a central element, an input arm and an output arm. The central element has four sides and a top and bottom. The input arm and an output arm each have a head portion for connecting with the central element and a body portion. The head portion of each of the input and output arms defines a bearing surface having a first radius. The input and output arms engage the central element such that the bearing surfaces of the heads are offset by 90 degrees.