Flexible Coupling Assembly for Axial Load and Misalignment Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flexible coupling systems face challenges in efficiently transmitting power between gearboxes with high angular and axial misalignments, requiring improved structural features and economic viability.
Innovation Solution
A flexible coupling assembly featuring a quill shaft with a locking flange, radial displacement limiter, and flange adapters that allow for axial load distribution and misalignment accommodation, eliminating the need for ball and socket assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a sliding spline is utilized to limit axial load on the shaft elements, then axial load capacity is improved, but the coupling's ability to handle angular misalignment is reduced
Solution Approach 1:
The coupling is segmented into two independent load paths: a sliding spline for axial load and a quill shaft for angular misalignment accommodation. This segmentation allows each component to specialize in one function without compromising the other, resolving the contradiction between axial load capacity and angular misalignment handling.
Solution Approach 2:
The quill shaft acts as an intermediary element that provides a separate load path for angular misalignment forces, allowing the sliding spline to focus on axial load while the quill shaft handles the misalignment accommodation through its telescopic movement capability.
2Reliability
If a quill shaft with locking flange and radial displacement limiter is used, then reliability and MTBMA are improved, but device complexity increases
Solution Approach 1:
The quill shaft incorporates a radial displacement limiter that allows controlled dynamic movement within defined limits. This dynamic constraint mechanism prevents excessive movement that would cause failure while maintaining simplicity through a single-component design, improving reliability without proportionally increasing complexity.
Solution Approach 2:
The locking flange with radial protrusions and cutouts provides self-aligning and self-locking functionality during assembly and operation. This self-service mechanism reduces the need for additional complex fastening components while ensuring reliable connection and maintaining structural integrity over extended maintenance intervals.
3Ease of operation
If flange adapters are welded to the diaphragm coupling and bolted to the primary coupling shaft, then ease of assembly is improved, but manufacturing complexity increases
Solution Approach 1:
The flange adapter merges multiple functions into a single component: it provides a welding interface to the diaphragm coupling, a bolting interface to the primary coupling shaft, and alignment features through pin holes. This consolidation simplifies assembly by reducing the number of separate parts while the standardized interfaces keep manufacturing complexity manageable.
Solution Approach 2:
The flange adapter serves multiple purposes: structural connection, alignment reference, and load transfer. This multi-functionality reduces the total component count and simplifies the assembly process while maintaining manufacturability through standardized features that can be produced using conventional machining and welding processes.
Data Source
Figure 1
Figure 1a
Figure 1b
AI summary
A flexible coupling assembly for a power transmission system including a first shaft (102) defining an axis (104), configured for connecting to a first rotating member (101a), the first shaft adjoining and passing through a first flexible diaphragm coupling (106) and lockably connecting to a quill shaft (108) by a locking flange (110) and the quill shaft being configured for connecting to a second rotating member (101b), including a first mating portion (112) for receiving the locking flange of the first shaft within a circumferential opening, wherein the quill shaft (108) is disposed within a primary diaphragm coupling shaft (109).