Coded Plug-In Shaft Coupling for Preserving Commutation Angle
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Solution Overview
Problem
Existing plug-in shaft couplings for servo motors allow for variable angular positions, leading to the loss of commutation angle information when the encoder is disassembled and reassembled, requiring time-consuming reconfiguration during motor or encoder replacements.
Innovation Solution
A coded plug-in shaft coupling with a first and second coupling element and an intermediate element that compensates for misalignment, featuring angle coding through recesses and extensions, ensuring the coupling elements can only connect in a predefined angular position, thus maintaining the commutation angle correlation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a conventional plug-in shaft coupling is used, then the motor or encoder can be replaced, but the commutation angle information is lost and reconfiguration is required
Solution Approach 1:
The coupling elements are pre-coded with angular position information through asymmetric recesses and extensions during manufacturing. This preliminary encoding ensures that when the encoder is replaced, the pre-existing coding automatically guides correct angular alignment without requiring time-consuming reconfiguration or commutation setting procedures.
Solution Approach 2:
The asymmetric coding features (recesses and extensions) act as an intermediary mechanism between the encoder shaft and motor shaft. This intermediary coding system transfers the angular position information from the original assembly to the replacement component, enabling automatic preservation of commutation angle without direct measurement or adjustment.
2Ease of operation
If a conventional plug-in shaft coupling is used, then assembly is flexible, but angular position precision cannot be maintained
Solution Approach 1:
The coupling elements incorporate asymmetric coding features including recesses of different depths and extensions of different lengths. This asymmetry creates a unique angular position that can only be achieved in one orientation, thereby maintaining precise angular position (commutation angle) while preserving ease of assembly through the plug-in design.
Solution Approach 2:
The coding features are localized to specific regions of the coupling elements rather than requiring precision throughout the entire assembly. The asymmetric recesses and extensions are concentrated at specific angular positions, allowing the majority of the coupling surface to remain simple and easy to assemble while maintaining precision at the critical coding locations.
3Ease of manufacture
If simple coupling elements are used, then assembly is easy, but torsional stiffness is insufficient
Solution Approach 1:
The coupling system is divided into separate coupling elements (first and second coupling elements) that can be manufactured independently with simple geometries. Despite this segmentation into simple parts, the overall assembly achieves high torsional stiffness through the precise angular positioning enabled by the coding features and the rigid connection between elements, combining ease of manufacture with mechanical strength.
Data Source
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AI summary
The present invention relates to a coded plug-in shaft coupling, comprising: a first coupling element (2), designed to be fixedly arranged at an end of a first shaft, a second coupling element (3)), designed to be fixedly arranged at an end of a second shaft, an intermediate element (10) for a mechanical and torsionally-rigid connection of the first and second coupling elements (2, 3), the intermediate element (10) compensates for an axial, radial and angular misalignment between the two shafts, wherein the first and second coupling elements (2, 3) and the intermediate element (10, 110) are formed in such a way that the first coupling element (2) and second coupling element (3) are to be connected only one predefined angular position.