Elastic Double Torsional Coupling for Rail Vehicle Drive Systems
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Solution Overview
Problem
Existing elastic double torsion couplings for rail vehicles are unsuitable for the drive side due to their large axial dimensions and weight, which cause imbalance, vibration, and noise issues at high speeds, and require complex assembly and disassembly for maintenance.
Innovation Solution
A flat plate design for the intermediate piece with radially extending arms and a convex outer surface on the connecting flange, allowing for compact size, reduced weight, and easier maintenance by enabling lateral removal and reinsertion of tabs without disassembling the entire coupling, along with telescoping sliding pieces to accommodate varying axial distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a tubular connecting piece with considerable axial length is used to prevent excessive deflection angle, then the coupling can accommodate shaft misalignment, but the axial dimensions and weight increase, causing imbalance, vibration, and noise at high speeds
Solution Approach 1:
The coupling is divided into two separate torsion couplings connected by a flat intermediate piece, allowing each torsion coupling to handle misalignment independently while the flat intermediate piece minimizes axial length and weight
Solution Approach 2:
The intermediate piece is designed as a flat plate rather than a tubular structure, changing the dimensional approach from axial length to radial thickness, thereby reducing weight and moment of inertia while maintaining misalignment accommodation through the flexibility of the torsion couplings themselves
2Adaptability or versatility
If a tubular connecting piece with considerable axial length is used to prevent excessive deflection angle, then the coupling can accommodate shaft misalignment, but the axial dimensions increase, causing space constraints on the drive side
Solution Approach 1:
The coupling is segmented into two torsion couplings with a flat intermediate piece, distributing the misalignment accommodation function to the torsion couplings while the intermediate piece serves only as a lightweight connector with minimal axial length
Solution Approach 2:
The intermediate piece transitions from a tubular form (axial dimension) to a flat plate form (radial dimension), dramatically reducing axial length while maintaining structural integrity and enabling compact installation on the drive side
3Stability of the object's composition
If the entire double torsion coupling is designed as a single integrated unit, then structural integrity is maintained, but assembly and disassembly for maintenance require complete disassembly, increasing maintenance time and complexity
Solution Approach 1:
The coupling is segmented into two torsion couplings connected by an intermediate piece with receptacles, allowing the lugs of one torsion coupling to be accessed and removed laterally without disassembling the entire coupling, while the overall structure remains integrated during operation
Solution Approach 2:
The intermediate piece acts as an intermediary component with receptacles that facilitate lateral access to the lugs, enabling maintenance personnel to remove and replace lugs independently while the coupling remains installed on the drive side
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 the axial length and mass of the coupling, simplifies maintenance, and effectively manages high-speed vibrations and noise, while allowing for efficient repair and adaptation to different shaft alignments without compromising torque transmission.
Implementation Method 1
The lugs incorporate elastic elements, so-called silent blocks
Implementation Method 2
their purpose is to isolate vibrations and acoustically decouple the two shafts from each other
Implementation Method 3
Elastic, non-switchable torsion couplings are used to transmit torque between two shaft connections
Implementation Method 4
The intermediate piece is connected to the opposite end of each of the lugs
Data Source
Figure 1
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AI summary
The invention relates to a rail vehicle with an output shaft of an electric motor and an input shaft of a gearbox and a double torsion coupling (1) by means of which the output shaft is connected to the input shaft, wherein the double torsion coupling (1) has two torsion couplings (2, 3) which are rotationally connected to each other by an intermediate piece (4), wherein the two torsion couplings (2, 3) each have a connecting flange (5) and a plurality of lugs (6), wherein the distance between the two torsion couplings (2, 3) is selected such that the lugs (6) of each torsion coupling (2, 3) can be removed for repair purposes without having to dismantle the entire double torsion coupling (1) from its place of use on the rail vehicle, and wherein the lugs (6) have an elastomeric body in which a force-transmitting filament package is embedded.