Flanged Coupling Member Axial Length Reduction
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Solution Overview
Problem
Conventional power transmission devices face challenges in reducing machining costs, weight, and axial dimension while maintaining torque transmission efficiency, particularly due to high machining costs, strength limitations, and weight savings issues related to bolted flange structures.
Innovation Solution
A power transmission device featuring a tubular first rotator with a recess or projection, a shaft-shaped second rotator, a clutch mechanism, and a flanged coupling member with a shaft portion and engagement portion that prevents relative rotation, allowing for coaxial bolt insertion and reducing the need for bolt holes, thereby minimizing axial length and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bottom portion of the first rotator is fastened to the flange portion by bolts with through holes, then the connection strength is sufficient, but the axial length and weight increase due to the need for thick flange portions and bolt holes
Solution Approach 1:
Instead of forming bolt holes in the flange portion and bottom portion of the first rotator, the invention inverts the approach by forming the bolt hole only in the flanged coupling member's shaft portion. The bolt is inserted from the inner side of the first rotator through the shaft portion to the flange portion, eliminating the need for through holes in the first rotator and reducing axial length requirements.
Solution Approach 2:
The invention changes the dimensional approach by moving the bolt hole formation to a different location (the flanged coupling member's shaft portion) rather than in the flange portion itself. This allows the flange portion to be thinner while maintaining connection strength, as the bolt passes through the shaft portion which has sufficient thickness.
2Strength
If the bottom portion of the first rotator is fastened to the flange portion by bolts, then the connection is secure, but the manufacturing complexity and cost increase due to the need for bolt holes and thick flange portions
Solution Approach 1:
The invention inverts the conventional approach by forming the bolt hole in the flanged coupling member instead of in the first rotator. This simplifies manufacturing of the first rotator (allowing flow forming without hole formation) while maintaining secure connection through the bolt passing through the shaft portion to the flange portion.
3Device complexity
If an input shaft portion projects from the outer surface of the bottom portion of the first rotator, then the structure is simple, but the machining cost increases and flow forming cannot be employed
Solution Approach 1:
The invention extracts the input shaft function from the first rotator itself and places it in a separate flanged coupling member. This allows the first rotator to be manufactured by simple flow forming without complex machining, while the input shaft portion exists as a separate component in the flanged coupling member that can be manufactured independently.
4Weight of moving object
If the first rotator is formed of aluminum alloy to reduce weight, then the weight decreases, but the torque transmission capability through a small diameter input shaft portion is insufficient
Solution Approach 1:
The invention segments the functional requirements by separating the lightweight aluminum alloy first rotator from the torque transmission input shaft portion. The first rotator can be made of lightweight aluminum alloy, while the input shaft portion in the flanged coupling member can be made of stronger material or have a larger diameter to handle torque transmission requirements.
Data Source
AI summary
A flanged coupling member is provided with a shaft portion to which a drive force is input, and a flange portion formed in one end of the shaft portion. The flanged coupling member is coupled to a front housing member with a bolt in which a shaft portion thereof is coaxially arranged in a front housing member and a flange portion contacts an outer surface in an axial direction of a bottom portion of the front housing member. The flange portion is provided with a tubular engagement portion that extends in an axial direction from an outer peripheral edge thereof. The engagement portion is arranged on an outer circumference of the front housing member on the basis of the fastening, and the engagement portion and the front housing member are engaged via a spline. The flanged coupling member is fastened to the front housing member at the shaft portion.