Flexible Coupling Element Reducing Axial Space
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Solution Overview
Problem
Existing flexible coupling elements for shaft arrangements in automotive drive trains require significant installation space and material, limiting their torque transmission capacity and longevity due to self-aligning torque and vibration issues.
Innovation Solution
A flexible coupling element design featuring primary and secondary loop bundles, where the secondary loop bundle is fastened to support arrangements rather than wrapping around bushings, reducing axial space requirements and material usage, while ensuring homogeneous force application and improved torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If loop bundles wrap around bushings to transmit torque, then torque transmission capacity is improved, but installation space requirement increases
Solution Approach 1:
The coupling element is divided into multiple bushings (at least three) arranged around the central axis, with loop bundles selectively connecting specific bushings. This segmentation allows torque transmission through multiple discrete paths while reducing the overall volume compared to a single large loop bundle design.
Solution Approach 2:
The loop bundles are configured to extend primarily in the radial direction between bushings rather than wrapping around them in the circumferential direction. This dimensional change from circumferential wrapping to radial extension reduces the axial and radial envelope dimensions, decreasing installation space while maintaining torque transmission capability.
2Reliability
If more material is used in the coupling element, then torque transmission capacity and lifetime are improved, but installation space and cost increase
Solution Approach 1:
The loop bundles are strategically positioned to connect specific bushings based on their loading conditions. Not all bushings are connected to all loop bundles, allowing material to be concentrated where it is most needed for torque transmission and vibration damping, rather than uniformly distributed throughout the entire coupling structure.
Solution Approach 2:
The coupling element combines different materials with complementary properties: metallic bushings for structural support and torque transmission, elastic loop bundles for vibration damping and flexible connection, and a rubber cover for protection and additional damping. This composite approach achieves high reliability without requiring excessive material in any single component.
3Power
If loop bundles are configured to wrap around bushings, then torque transmission is improved, but self-aligning torque and vibration issues worsen
Solution Approach 1:
Instead of wrapping loop bundles around bushings (which creates self-aligning torque), the invention inverts the configuration by having loop bundles extend radially between bushings and be guided by support arrangements. This reversal eliminates the wrapping action that generates harmful self-aligning torque while maintaining the torque transmission function through direct linear connection between bushings.
Solution Approach 2:
Support arrangements are introduced as intermediary structures that guide the loop bundles between bushings. These support arrangements constrain the loop bundles to move primarily in the axial direction, preventing lateral movements that would generate vibration and self-aligning torque, while still allowing effective torque transmission through the loop bundles.
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 design reduces installation space and material needs, enhances torque transmission capacity, and extends the coupling element's lifespan by minimizing self-aligning torque and improving vibrational separation between shaft segments.
Implementation Method 1
a flexible rubber cover (12), in which a plurality of bushings (14) and a plurality of flange elements (16) arranged on the bushings (14) are embedded in at least some sections
Implementation Method 2
The loop bundles, the support arrangements and the bushings are embedded in a flexible rubber cover
Data Source
AI summary
A flexible coupling element for a shaft arrangement for articulated connection of two shaft sections. The flexible coupling element has a plurality of bushings, at least one primary loop bundle a support arrangement arranged on at least one bushing for axial guidance of the at least one primary loop bundle, and an elastic cover. The at least one primary loop bundle, the at least one support arrangement and the plurality of bushings are embedded at least partially in the elastic cover. With this flexible coupling element, it is also provided that the at least one primary loop bundle is wrapped around two neighboring bushing pair Neighboring bushing pairs are joined together by means of at least one secondary loop bundle which is secured separately on the at least one support arrangement.