Conical Shaft Coupling for Low-Wear Planetary Gearbox Assembly
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Solution Overview
Problem
Existing coupling systems between operating machines and planetary gearboxes face issues such as fatigue wear, high manufacturing costs, and complex disassembly, particularly with grooved and flange joints, and friction joints that are not cost-effective or easy to use.
Innovation Solution
A coupling system utilizing truncated cone-shaped coupling portions and friction reducing elements like roller or ball bearings, allowing for stable and cost-effective connection between the machine shaft and the planetary gearbox, facilitating easy assembly and disassembly while reducing friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If grooved connection is used to couple machine shaft with planetary gearbox shaft, then assembly and disassembly is simplified, but fatigue wear and fretting occur causing premature damage
Solution Approach 1:
The invention extracts the harmful grooved connection interface that causes fretting wear and replaces it with a frustoconical surface connection. The grooved connection is completely removed from the coupling system, eliminating the source of fatigue wear while maintaining assembly simplicity through the tapered interface design.
Solution Approach 2:
The invention changes the geometric parameters of the coupling interface from a cylindrical grooved connection to a frustoconical surface connection with specific angle ranges (30-60 degrees). This parameter change transforms the contact mechanics from point/line contact prone to fretting to distributed surface contact that resists wear while maintaining ease of assembly.
2Reliability
If flange joints are used to constrain cylindrical shafts together, then resistance to damage and prolonged use is improved, but manufacturing costs and overall dimensions increase
Solution Approach 1:
The invention segments the coupling function into two distinct parts: the frustoconical connection surfaces for torque transmission and wear resistance, and the retaining means for axial positioning. This segmentation allows each component to be optimized independently, reducing manufacturing complexity compared to large flange joints while maintaining durability.
Solution Approach 2:
Instead of using large flange joints that extend outward from the shafts, the invention inverts the approach by using tapered surfaces that converge inward, creating a compact coupling that achieves the same protective function with reduced dimensions and lower manufacturing costs.
3Reliability
If friction joints are used to clamp machine shaft, then axial sliding is counteracted, but disassembly is greatly complicated
Solution Approach 1:
The invention introduces a retaining means as an intermediary element that mediates between the frustoconical connection surfaces and the shaft. This retaining component simplifies disassembly by providing a clear removal path while maintaining axial constraint during operation, avoiding the need to dismantle complex friction joint structures.
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 system provides a robust, cost-effective, and easy-to-use coupling solution that minimizes wear and manufacturing costs, ensuring prolonged system life and efficient operation.
Implementation Method 1
friction reducing elements (7) placed between the load-bearing structure (6) and the slow gearbox shaft (5) and adapted to allow the latter to rotate with respect to the former by reducing the friction thereof
Data Source
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AI summary
The coupling system (1) between an operating machine and a planetary gearbox comprises: - an axially rotatable machine shaft (2) of an operating machine; - a slow gearbox shaft (5) of a planetary gearbox (3) connectable integrally in rotation with the machine shaft (2) in an operational configuration; wherein the machine shaft (2) and the slow gearbox shaft (5) comprise a first coupling portion (11) and a second coupling portion (12), respectively, substantially truncated cone-shaped and complementary to each other, the first coupling portion (11) and the second coupling portion (12) being conically coupled to each other in the operational configuration.