Coupling Assembly Torque Density via Extraction
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Solution Overview
Problem
Existing coupling assemblies face limitations in torque density due to the need for large clearance for nut wrenches, which restricts the maximum shaft size and overall diameter, leading to reduced torque capacity.
Innovation Solution
A coupling assembly design featuring a bushing system that eliminates the need for nuts by using rotationally fixed bushings with non-circular apertures, allowing for a larger diameter and increased torque density, along with an anti-slip arrangement to manage misalignment and enhance torque transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If nuts are used for fasteners in coupling assembly, then fastening connection is achieved, but large clearance is required for wrench operation which reduces the outer diameter and torque density
Solution Approach 1:
The patent extracts and eliminates the nut component from the fastening system. Instead of using traditional bolt-nut connections, the invention uses bolts with integrated hexagonal heads that directly engage with hexagonal recesses in the coupling components, removing the need for nuts and the associated wrench clearance requirements.
Solution Approach 2:
The patent merges the fastening function and the torque transmission function into a single integrated component. The hexagonal bolt head serves both as the fastening element and as the torque transmission interface, eliminating the separate nut component and reducing the overall diameter requirement.
2Ease of operation
If large clearance is provided for nut wrenches, then wrench operation is facilitated, but the outer diameter of the coupling assembly must be reduced
Solution Approach 1:
The patent removes the nut component entirely from the assembly, eliminating the need for wrench clearance around the nut perimeter. The hexagonal bolt head design allows for compact tool engagement without requiring the large radial clearance that would be needed for nut wrenches.
Solution Approach 2:
Instead of having the nut protrude outward requiring clearance for wrench application, the patent inverts the approach by having the hexagonal engagement surface recessed or integrated into the bolt head, allowing tool engagement without compromising the outer diameter of the coupling assembly.
3Area of stationary object
If the outer diameter is reduced to accommodate wrench clearance, then clearance is available, but the bore diameter to coupling diameter ratio and torque density are reduced
Solution Approach 1:
By extracting the nut component, the patent eliminates the need for large clearance areas around fasteners. This allows the coupling assembly to maintain a larger outer diameter for the same bore size, thereby increasing the bore diameter to coupling diameter ratio and improving torque density.
Solution Approach 2:
The patent changes the geometric parameters of the fastening system by replacing the nut-with-wrench-clearance design with a hexagonal bolt head design. This parameter change allows for more efficient use of the coupling diameter, increasing both the bore diameter to coupling diameter ratio and the torque density.
Data Source
AI summary
A coupling assembly includes a body member and at least one end member attached to the body member. At least one connection arrangement is situated between the body member and the at least one end member, respectively. The at least one connection arrangement includes a plurality of bushings. A plurality of fasteners are each respectively received by the plurality of bushings to fasten the body member to the at least one end member. Each one of the plurality of bushings are rotationally fixed about their center longitudinal axes by the at least one connection arrangement.