Corrugated Torque Coupling for Misalignment Without Lubrication
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Solution Overview
Problem
Existing couplings face challenges in achieving low friction, dynamic stress resistance, and cost-effectiveness while accommodating misalignment between rotary components, particularly in aeronautic applications where weight minimization is crucial, and often require complex manufacturing and assembly processes.
Innovation Solution
A coupling design featuring a female and male member with a corrugated coupling member having alternating outer and inner folds, which are connected via respective connections, allowing for compression and accommodating misalignment through elastic deformation, and can be formed using a plastic deformable material shaped into an annular configuration using forming gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional coupling designs are used to accommodate misalignment, then misalignment tolerance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The coupling member is segmented into multiple folds (first folds and second folds) that can independently deform, allowing the coupling to accommodate misalignment through distributed deformation rather than requiring a single complex articulated structure
Solution Approach 2:
The coupling member is designed as a flexible thin-walled structure that can elastically deform under misalignment conditions, eliminating the need for rigid articulated joints or complex clearance mechanisms while maintaining misalignment tolerance
2Reliability
If lubrication and cooling systems are added to reduce friction and meet operational requirements, then operational performance is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The coupling design allows the folds to self-lubricate through material properties and self-cool through elastic deformation during operation, eliminating the need for external lubrication systems and cooling mechanisms while maintaining reliable operation under varying conditions
3Manufacturing precision
If alignment tolerance is reduced to improve torque transfer precision, then torque transfer efficiency is improved, but ease of assembly deteriorates
Solution Approach 1:
The coupling member's material and geometric parameters are optimized to allow elastic deformation within a controlled range, enabling the coupling to maintain precise torque transfer while accommodating reasonable misalignment during assembly without requiring ultra-precise alignment procedures
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 design enhances torque transfer efficiency, reduces manufacturing and assembly complexity, and accommodates misalignment effectively, while minimizing weight and maintaining performance under varying operational conditions without the need for lubrication or cooling.
Implementation Method 1
allowing for compression and accommodating misalignment through elastic deformation
Data Source
AI summary
The coupling can have a female member having a plurality of female member connections circumferentially arranged along a radially inner face; a male member having a plurality of male member connections circumferentially arranged along a radially outer face; and a coupling member extending annularly around the axis, the coupling member having a strip, the strip having, circumferentially relative the axis, an alternating sequence of outer folds and inner folds, the outer folds connected to the female member via respective ones of the female member connections, the inner folds connected to the male member via respective ones of the male member connections, the inner folds being circumferentially offset from the outer folds in a given angular direction.