Compliant Joint Assembly With Dielectric Torque Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In actuated ball valve systems, particularly in aircraft water supply systems, there is a need for a dielectric barrier to prevent electrical faults from the motor end from being transmitted to the ball shaft, while maintaining torque transmission, especially when the ball shaft is jammed or frozen, and to avoid damage from water exposure.
Innovation Solution
A dielectric insert made of adhesive or epoxy resin is positioned between the drive shaft and the driven shaft, forming an insulating layer that extends into both shafts, providing a dielectric barrier and torque transfer member, which can be shaped with non-circular cross-sections like lobes or ribs to engage with corresponding recesses, and may use a support structure that can be made of lightweight non-conductive materials for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric barrier is provided between the drive shaft and driven shaft to prevent electrical faults, then electrical insulation is improved, but torque transmission capability deteriorates
Solution Approach 1:
The patent uses a composite structure consisting of a dielectric insert material (such as plastic or ceramic) combined with a torque transfer mechanism (keys, splines, or ribs). This composite approach allows the dielectric material to provide electrical insulation while the mechanical features embedded in or integrated with it enable torque transmission, thus resolving the contradiction between electrical insulation and torque transmission capability
Solution Approach 2:
The dielectric insert acts as an intermediary component between the drive shaft and driven shaft. It provides the dielectric barrier function while incorporating torque transfer features that allow mechanical power transmission. The insert mediates between the electrical insulation requirement and the torque transmission requirement, satisfying both functions simultaneously
2Strength
If metal parts are used for the ball shaft to satisfy durability standards, then strength is improved, but electrical conductivity increases causing fault transmission
Solution Approach 1:
The dielectric insert serves as a mediator between metal components. It allows the ball shaft and drive train to be made of durable metal materials while the dielectric insert breaks the conductive path, preventing electrical fault transmission. The insert is positioned at the interface where dielectric separation is needed, allowing metal-to-metal connections elsewhere for strength while providing insulation where required
Solution Approach 2:
The patent segments the drive train into conductive metal sections (for strength and durability) and a non-conductive dielectric section (for insulation). The dielectric insert creates a discontinuity in the conductive path while maintaining mechanical torque transmission, allowing the system to have both strong metal components and electrical insulation
3Object-affected harmful factors
If seals are provided between wet and dry parts to prevent water damage, then protection is improved, but torque transmission efficiency deteriorates
Solution Approach 1:
The patent merges the sealing function and torque transmission function into a single integrated dielectric insert component. Rather than having separate seals that might interfere with torque transmission, the dielectric insert itself provides both the water seal and the torque transfer path through its mechanical engagement features, eliminating the trade-off between protection and efficiency
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 dielectric insert effectively prevents electrical faults from reaching the ball shaft, ensures torque transmission even under resistance, and maintains the integrity of the dielectric barrier, ensuring the assembly remains functional and safe in wet environments.
Implementation Method 1
a dielectric insert positioned between the drive shaft and the driven shaft, the insert comprising a dielectric adhesive or epoxy resin material injected between the drive shaft and the driven shaft to form an insulating layer
Implementation Method 2
the insert comprising a dielectric adhesive or epoxy resin material injected between the drive shaft and the driven shaft
Data Source
AI summary
A method of forming a dielectric barrier and torque transfer member between a drive shaft and a driven shaft of a torque transfer assembly. The method includes assembling the drive shaft and the driven shaft in axially adjacent relationship to one another, the drive shaft and the driven shaft each having a recess formed therein such that when the shafts are assembled, the recesses cooperate to define a chamber extending across the interface between the drive and driven shaft and into the interior of both the drive and the driven shaft. The method further includes injecting a dielectric adhesive or resin material into the chamber to fill the chamber and to extend across the interface between the drive and the driven shaft, and curing the dielectric material to form a dielectric barrier between and to provide torque transfer between the drive and the driven shaft.