Coated Tenon-Groove Coupling for Low-Abrasion Gear Motors
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Solution Overview
Problem
Existing clutch arrangements in geared motors contribute to environmental pollution due to metallic particle abrasion and have limited durability, necessitating frequent replacement parts and increased energy consumption.
Innovation Solution
A clutch arrangement featuring a coated spring and sleeve design, where the spring partially projects into a groove on the sleeve, with a radial orientation and a coating that prevents direct metallic impact, allowing for torque transmission through a positive-locking connection and damping torque peaks, while also reducing axial impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a metallic spring and sleeve connection is used for torque transmission, then torque transmission efficiency is improved, but metallic particle abrasion occurs causing environmental pollution
Solution Approach 1:
A coating layer is applied to the spring as an intermediary substance between the metallic spring and the metallic sleeve. This coating layer prevents direct metallic contact during operation, thereby eliminating metallic particle abrasion while still allowing effective torque transmission through the coated surface.
2Device complexity
If a metallic spring and sleeve connection is used, then structural simplicity is maintained, but service life is limited requiring frequent replacement
Solution Approach 1:
The surface properties of the spring are changed by applying a coating layer. This coating modifies the physical and chemical parameters of the spring surface, providing enhanced wear resistance and durability without altering the basic metallic structure or requiring complex design changes.
3Reliability
If replacement parts are frequently required, then maintenance needs increase, but resource consumption and energy usage for production increase
Solution Approach 1:
The coating is applied to the spring during the initial manufacturing stage as a preliminary protective measure. This pre-applied coating prevents wear and extends service life before the component is put into operation, eliminating the need for frequent replacements and the associated resource consumption.
4Object-generated harmful factors
If a coating is applied to the spring, then environmental protection is improved by reducing particle release, but manufacturing complexity increases
Solution Approach 1:
The coating serves as an intermediary layer that can be applied using standard manufacturing techniques. While it adds a step to the manufacturing process, the coating application is a conventional surface treatment that does not require fundamentally new or complex manufacturing equipment or processes.
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 coating minimizes metallic particle release, extends clutch assembly life, reduces resource consumption for replacements, and enhances environmental protection by minimizing environmental impact and improving torque transmission efficiency.
Implementation Method 1
prevents direct impact with metallic areas. This prevents the abrasion of metallic particles
Implementation Method 2
the coating dampens torque peaks, i.e., torque surges, especially torque jerks
Implementation Method 3
the shaft is connected to the sleeve by means of the spring and the groove in the circumferential direction in a positive-locking manner. This is advantageous in that the torque is transmitted through the positive connection
Data Source
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AI summary
The invention relates to a coupling assembly, more particularly of a geared motor. The coupling assembly comprises a shaft (1), on which a tongue (5) is formed, and a sleeve (2), in which a groove (4) is formed, into which groove the tongue (5) at least partly reaches. The shaft (1) and the sleeve (2) can be rotated about an axis of rotation. The groove (4) and the tongue (5) each extend in the radial direction. The tongue (5) is at least partly provided with a coating (7).