Conical Shaft Coupling for Faster Gearbox Assembly and Removal
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Solution Overview
Problem
The assembly and disassembly of heavyweight gearboxes in drive devices for comminution devices and thermal treatment units are complex due to precise alignment requirements, often resulting in fit issues and the need for reworking during installation and removal.
Innovation Solution
A shaft with a conical end region that allows for the attachment of a hollow gear shaft, providing self-locking torque transmission and easy disassembly, using a clamping device with a conical inner surface for precise alignment and non-positive connection, and a hydraulic dismantling mechanism for quick detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gearbox is mounted onto a shaft using conventional alignment methods, then the connection can be secure, but the assembly process becomes complex and time-consuming due to precise alignment requirements
Solution Approach 1:
The shaft end region is designed with a conical surface instead of a cylindrical one. This conical geometry provides self-aligning properties during assembly, allowing the gearbox hollow shaft to automatically center itself on the drive shaft through the tapered surface, eliminating the need for complex external alignment tools and procedures while ensuring a secure, precise connection.
2Reliability
If a gearbox is mounted onto a shaft with precise alignment, then the connection is secure, but the disassembly process becomes equally complex and time-consuming
Solution Approach 1:
The conical surface geometry enables easy disassembly by allowing the hollow shaft to be simply pulled axially off the drive shaft. The tapered shape creates a wedge effect that, when combined with the clamping device release, allows the components to separate without requiring complex disassembly tools or procedures, significantly reducing maintenance time.
Solution Approach 2:
The connection system is divided into separable components: the drive shaft with conical end region, the hollow shaft with conical inner surface, and the clamping device. This segmentation allows the hollow shaft to be independently removed from the drive shaft by releasing the clamping device, enabling quick disassembly without affecting the entire gearbox or drive system.
3Ease of manufacture
If conventional cylindrical shaft ends are used, then the design is simple, but alignment errors cause fitting seizing and require reworking
Solution Approach 1:
The conical surface on the shaft end region provides self-aligning properties that compensate for minor misalignments during assembly. The tapered geometry guides the hollow shaft into proper alignment as it is pushed onto the drive shaft, preventing fitting seizing and eliminating the need for reworking, while maintaining manufacturing feasibility through standard conical machining 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
Facilitates simple and precise assembly of the gearbox, reduces installation time, and simplifies disassembly by compensating for alignment errors and allowing for easy replacement of wear-prone components without disassembling the entire transmission.
Implementation Method 1
The tapered design of the shaft ensures self-centering and collinear alignment of the shaft within the hollow shaft, thus compensating for any misalignment of the hollow shaft relative to the shaft.
Implementation Method 2
The inner surface of the hollow shaft is frictionally connected to the conical end region of the shaft. The clamping device applies a clamping force, particularly radial, to the hollow shaft to create the frictional connection.
Data Source
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AI summary
The present invention relates to a drive device (11) for driving a comminution device (10) for comminuting granular material or for driving a drum of a thermal treatment unit or a screen, having at least one shaft (36) which has an at least partially conical end region (38), a gearing mechanism (28, 30) being attached to an end region (38) of the shaft (36). The gearing mechanism (28, 30) has a hollow shaft (40) which is fastened on the end region (38) of the shaft (36) by means of a clamping device (42). The hollow shaft (40) has a conical inner face which is complementary to the end region (38) of the shaft (36), and the conical inner face of the hollow shaft (40) is connected frictionally to the conical end region (38) of the shaft (36).