Disc Pack Coupling Locking Mechanism for Energy-Free Contact Pressure
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Solution Overview
Problem
Disc pack couplings require continuous energy to maintain contact pressure between discs, leading to increased energy demand and potential hydraulic or electrical failures, which can cause seal loading and leakage issues.
Innovation Solution
A locking unit comprising a locking part, guide part, and actuating element, where the locking part is rotatable and axially displaceable, with slanted control surfaces that interact to move into stop positions, allowing for mechanical maintenance of contact pressure without actuating energy, enabling efficient torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic pistons are used to maintain contact pressure on the coupling discs, then the coupling can be reliably closed and opened, but continuous energy is required to maintain the contact pressure and the hydraulic system is subject to seal loading and leakage issues
Solution Approach 1:
The locking part is pre-loaded by a spring element to automatically engage with the guide part when the coupling is closed, maintaining contact pressure without requiring continuous hydraulic pressure. The locking elements are positioned in advance to take over the holding function as soon as the coupling discs are pressed together.
Solution Approach 2:
The hydraulic pressure maintenance system is replaced with a purely mechanical locking mechanism consisting of locking parts, guide parts with control surfaces, and spring elements. This mechanical substitution eliminates the need for continuous hydraulic energy input while maintaining the same reliability function.
2Stability of the object's composition
If actuating pressure is maintained permanently in the hydraulic system, then the locking unit can maintain the coupling in the closed state, but the supply lines and pressure chambers are loaded permanently which has a disadvantageous effect on the seals
Solution Approach 1:
The function of maintaining contact pressure is extracted from the hydraulic system and transferred to a separate mechanical locking unit. The hydraulic system is only used for actuation, while the locking mechanism with spring-loaded locking parts takes over the stable holding function, eliminating continuous pressure loading on seals.
Solution Approach 2:
The locking parts are self-actuating through spring elements that automatically engage the locking elements with the guide part when the coupling is closed. This self-service mechanism maintains stability without requiring continuous external hydraulic pressure, reducing seal loading.
3Stability of the object's composition
If locking elements are used to lock the closed disc pack coupling, then the coupling can be maintained in the closed or open state, but additional energy demand is produced to hold the coupling in the closed or open state
Solution Approach 1:
Spring elements provide a counteracting force that automatically engages the locking parts with the guide part, balancing the forces required to maintain the closed state. This mechanical counterweight system eliminates the need for continuous hydraulic pressure to hold the coupling state.
Solution Approach 2:
The locking mechanism operates in discrete states: the locking parts are engaged or disengaged from the guide part control surfaces through periodic actuation. Once engaged, the mechanical interlocking with slanted control surfaces maintains the state without continuous energy input, requiring energy only for state transitions.
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 solution reduces energy demand for maintaining contact pressure, enhancing the efficiency of the coupling/braking system and allowing for reliable operation in high-speed applications like electromobility, with no need for continuous actuation pressure.
Implementation Method 1
the locking part and the guide part comprise control surfaces which are interacting which with each other and which are positioned at a slant in relation to the rotational direction of the locking part and serve for moving the locking part into two stop positions
Data Source
AI summary
A disc pack coupling for torque transmission between shafts has coupling discs. A locking unit is provided that maintains a contact pressure acting on the coupling discs when the disc pack coupling is closed. The locking unit has a locking part, a guide part, an actuating element, and a pressure element. The guide part is non-rotatably and non-displaceably arranged in relation to a first shaft. The locking part has a locking part axis and is rotatable about and displaceable axially relative to the locking part axis. Locking part and guide part are provided with interacting control surfaces positioned at a slant to a rotational direction of the locking part. The control surfaces are provided to move the locking part into a first and a second stop position. In the first stop position, the locking part maintains the contact pressure on the coupling discs.