Fiber-Plastic Coupling Half for Mass Reduction in Drive Trains
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Solution Overview
Problem
Conventional coupling devices, particularly elastomer couplings, face challenges in reducing mass without compromising mechanical properties, leading to interference in measurement signals and unreal loads on test objects in drive train testing setups.
Innovation Solution
A coupling half and device featuring coupling elements made of fiber-plastic composite (FRP) materials, with a design that includes a thicker claw area for compressive force absorption and a thinner shaft area for reduced mass, allowing for a closed ring structure and optimized force distribution, and utilizing semi-finished products like prepregs for layer control and fiber orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional elastomer coupling elements are used, then sufficient mechanical strength and damping are achieved, but the mass of the coupling half is too high
Solution Approach 1:
The coupling element is made from fiber-reinforced plastic composite material consisting of a plastic matrix and reinforcing fibers (glass fibers, carbon fibers, aramid fibers, or basalt fibers). This composite material provides both the required mechanical strength and significant mass reduction compared to conventional elastomer materials.
Solution Approach 2:
The coupling element features varying wall thickness with different regions optimized for specific functions: a first region with greater wall thickness for strength and force absorption, and a second region with reduced wall thickness for mass reduction. This local quality variation allows the component to meet strength requirements only where necessary.
2Reliability
If the mass of coupling elements is reduced, then natural frequencies are shifted to non-critical ranges, but the ability to absorb compressive forces is compromised
Solution Approach 1:
The coupling element has a first region with greater wall thickness specifically designed to absorb compressive forces generated during operation, while a second region has reduced wall thickness to lower overall mass. This local differentiation ensures compressive force absorption capability is maintained in critical areas while achieving mass reduction overall.
Solution Approach 2:
The fiber-reinforced plastic composite material provides high specific strength (strength-to-weight ratio), allowing the coupling element to maintain sufficient compressive force absorption capacity with reduced mass compared to conventional materials.
3Weight of moving object
If uniform wall thickness is used throughout the coupling element, then manufacturing is simplified, but mass cannot be optimized and strength is over-engineered in non-critical areas
Solution Approach 1:
The coupling element features varying wall thickness with different regions optimized for specific functions: a first region with greater wall thickness for strength and force absorption, and a second region with reduced wall thickness for mass reduction. This local quality variation allows the component to meet strength requirements only where necessary.
Solution Approach 2:
The coupling element is divided into distinct regions (first region and second region) with different wall thicknesses, allowing each region to be optimized independently for its specific functional requirements while maintaining overall structural integrity.
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
Significantly reduces the mass of the coupling half, altering natural resonance and enhancing the operation of drive trains, especially in test benches with sensitive measuring devices, while maintaining reliable torque transmission and structural integrity.
Implementation Method 1
at least one of the coupling elements (3) being made of a fiber-plastic composite (FRP)... This is a material consisting of reinforcing fibers and a plastic matrix. The matrix surrounds the fibers, which are bound to the matrix by adhesive or cohesive forces.
Implementation Method 2
A claw coupling is used to transmit rotary movements or torques with the help of a positive connection, which can be separated if necessary.
Implementation Method 3
it is also possible to insert elastomer elements between opposing claws of two coupling halves, which allows a certain relative mobility and damping between the coupling halves.
Data Source
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AI summary
The invention relates to a clutch half (1) having a plurality of clutch elements (3), wherein each clutch element (3) comprises a freely axially protruding dog region (4) and a shaft region (5). The clutch elements (3) are distributed on the circumference of a circle, wherein at least one of the clutch elements (3) is composed of a fiber composite material. In particular, the clutch element (3) is formed of a plurality of layers of a fiber composite semi-finished product, wherein the number of layers in the shaft region (5) is less than the number of layers in the dog region (4). The clutch elements (3) are held together by means of a clamping ring (7).