One-Piece Double Cardanic Gear Coupling for Lower Mass
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Solution Overview
Problem
Existing double cardanic gear couplings, such as the FLENDER ZBG series, are robust but have high manufacturing costs, significant mass, and complex component structures, which limit their dynamic properties and maintenance accessibility.
Innovation Solution
A one-piece, hollow-cylindrical connecting member with external teeth replaces the traditional two-piece design, featuring a screw connection for reduced mass and complexity, allowing for a more compact and easily maintainable gear coupling with improved dynamic properties and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional two-piece connecting member design is used, then the coupling provides sufficient structural strength and load-bearing capacity, but the manufacturing costs increase, mass increases, and component complexity increases
Solution Approach 1:
The patent merges two separate connecting member parts into a single integrated connecting member that directly connects the two coupling halves. This eliminates the need for intermediate components and simplifies the overall structure while maintaining the necessary load-bearing capacity through optimized geometry and material distribution in the unified component.
Solution Approach 2:
The connecting member is designed with a hollow-cylindrical structure that segments the material distribution, placing material only where structurally necessary. This reduces unnecessary mass and manufacturing complexity while preserving strength in critical load-bearing regions, allowing the component to be both simpler and lighter than traditional solid two-piece designs.
2Strength
If a solid cylindrical connecting member is used, then the load-bearing capacity is maintained, but the mass increases significantly
Solution Approach 1:
The connecting member employs local quality by using a hollow-cylindrical structure with strategically positioned walls and features. Material is concentrated in regions experiencing highest stress loads while leaving hollow spaces in lower-stress areas, thereby maintaining load-bearing capacity with significantly reduced mass compared to a uniform solid cylindrical design.
3Reliability
If multiple components are used in the coupling design, then the structural integrity is ensured, but the manufacturing costs and maintenance complexity increase
Solution Approach 1:
The invention combines multiple separate components (coupling halves and connecting members) into a simplified assembly where the hollow-cylindrical connecting member integrates the functions of multiple traditional parts. This reduces the total component count, lowers manufacturing costs through fewer production steps and less assembly, while maintaining structural integrity through the optimized monolithic design of the connecting element.
4Volume of moving object
If a compact design is implemented, then the space requirement is reduced, but the risk of collision during operational displacements increases
Solution Approach 1:
The coupling design incorporates dynamic characteristics by allowing the hollow-cylindrical connecting member to accommodate radial, axial, and angular displacements through its geometric design. The structure flexibly adapts to operational movements and misalignments, providing sufficient clearance and compliance to prevent collisions even in a compact configuration, thereby maintaining reliability while minimizing space requirements.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a double-cardan type gear coupling. It comprises a first internally toothed (208a) coupling part (201) for rotationally fixed connection to a driving shaft, a second internally toothed (208b) coupling part (203) for rotationally fixed connection to a driven shaft, and a cylindrical connecting element (205). The connecting element has a convex external toothing (207a, 207b) at each of its two end regions, one of which (207a) engages the internal toothing (208a) of the first coupling part (201) and the other (207b) engages the internal toothing (208b) of the second coupling part (203). At least one of the two internally toothed coupling parts (201, 203) has a flange (230) for forming a rotationally fixed flange connection with the corresponding shaft. Furthermore, the externally toothed connecting element (205) is formed in one piece.