Flexible Drive Coupling With Oblique Contact Surfaces for High Torque
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Solution Overview
Problem
Existing flexible couplings for drive trains face limitations in torque transmission capacity, misalignment handling, and durability due to the use of elastomers, thin plate members, and bellows designs, which can fail under high loading or fatigue, and universal joints concentrate load on few needle roller bearings.
Innovation Solution
A coupling assembly comprising a connector with slots and sockets, and yokes with pivots, allowing for manual assembly and torque transfer through complementary contact surfaces that distribute load effectively, enabling rotation and alignment adjustments without the need for tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomer inserts are used in flexible couplings, then the coupling can handle misalignment between shafts, but the torque transmission capacity is limited and the elastomer can fail under high loading
Solution Approach 1:
The coupling is divided into multiple rigid elements (first rigid element, second rigid element, third rigid element) connected by separate pivots, allowing each component to be optimized for strength while collectively providing misalignment accommodation through the articulated structure
Solution Approach 2:
The coupling combines rigid materials (metal components) with pivot mechanisms to create a composite structure that maintains high torque transmission capacity while accommodating misalignment, replacing the single-material elastomer approach with a multi-material rigid-rod mechanism
2Strength
If thin plate members are used to provide flexibility, then larger torque can be transmitted compared to elastomeric couplings, but the plate members can fatigue and fail over time
Solution Approach 1:
The flexible coupling mechanism is segmented into discrete rigid elements connected by pivots, eliminating continuous thin plate structures that are prone to fatigue, while maintaining the ability to transmit large torque through the rigid components
Solution Approach 2:
The pivot joints are designed to accommodate misalignment before it can cause stress concentrations in the torque transmission path, preventing fatigue failure by distributing stresses evenly across the rigid elements throughout the coupling's operational life
3Adaptability or versatility
If bellows type flexible center portion is used, then the entire coupling can flex, but the torque transmission capacity is limited
Solution Approach 1:
The coupling is segmented into multiple rigid elements (first, second, and third rigid elements) connected by pivots, allowing each element to maintain high strength for torque transmission while the articulated arrangement provides the necessary flexibility to accommodate misalignment
4Adaptability or versatility
If universal joints with needle roller bearings are used, then large misalignments can be handled, but the load is concentrated on only a few bearings
Solution Approach 1:
The coupling is segmented into multiple rigid elements connected by pivots, distributing the load across multiple pivot points rather than concentrating it on a few needle roller bearings, while still accommodating large misalignments through the articulated structure
Data Source
AI summary
A flexible coupling for a drive train, the coupling having a drive yoke, a driven yoke, and a connector for transferring rotational torque between the yokes. The drive and driven yokes are manually inserted into slots in the connector. The drive yoke connects to a drive shaft and the driven yoke connects to a driven shaft. Rotating the drive shaft rotates the drive yoke against the connector causing it to rotate; which in turn transfers torque to and rotates the driven yoke. Surfaces on the yokes and connector that contact one another during rotation define contact surfaces. Portions of the yokes and/or connector having the contact surfaces are obliquely profiled so that contact surfaces on the yokes are complementary to corresponding contact surfaces on the connector, which increases the areas of force transfer between the yokes and connectors.