Flexible Shaft Coupling Assembly for Axial Misalignment Torque Transfer
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Solution Overview
Problem
Power steering systems using a worm and worm gear often experience torque diminishment or loss due to incidents with the coupling between the motor shaft and the worm shaft, leading to instability in steering assistance.
Innovation Solution
A coupling assembly with a flexible coupling and adapters is introduced, providing a mechanical interlock and axial compliance between the motor shaft and the worm shaft, ensuring a redundant connection that maintains torque transfer even in case of incidents, using a flexible coupling and adapters to restrict relative motion while allowing axial and torsional compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid coupling is used between motor shaft and worm shaft, then torque transfer is efficient, but axial misalignment causes torque loss or failure
Solution Approach 1:
The patent employs a flexible coupling comprising a flexible membrane with circumferential and radial undulations. This flexible shell structure accommodates axial misalignment between motor shaft and worm shaft while maintaining torque transfer, resolving the contradiction between rigid torque transmission and axial compliance.
Solution Approach 2:
The flexible coupling changes its geometric parameters dynamically through the undulating membrane structure, allowing it to deform and adapt to axial misalignment conditions while continuing to transmit torque effectively.
2Adaptability or versatility
If a flexible coupling is used to accommodate misalignment, then axial compliance is improved, but coupling complexity increases
Solution Approach 1:
The flexible coupling is segmented into multiple undulations around the circumference, with each segment contributing to the overall flexibility. This segmentation allows the coupling to accommodate misalignment through distributed deformation rather than requiring a single complex mechanism.
Solution Approach 2:
The flexible membrane incorporates circumferential and radial undulations that create curved, spherical-like surfaces. These curved geometries naturally accommodate misalignment through geometric deformation, providing axial compliance without complex mechanical components.
3Adaptability or versatility
If the coupling is made more compliant to handle misalignment, then adaptability improves, but torque transfer efficiency may diminish
Solution Approach 1:
The flexible membrane with undulating structure provides compliance for misalignment while maintaining sufficient structural integrity for torque transfer. The thin film design allows deformation for adaptability while the continuous membrane structure ensures power transmission.
Solution Approach 2:
The coupling utilizes a composite structure combining flexible membrane material with reinforcing elements, creating a material system that simultaneously provides the flexibility needed for misalignment accommodation and the strength required for efficient torque transfer.
Data Source
AI summary
A coupling assembly includes a flexible coupling and a first adapter. The flexible coupling defines an opening that extends along a central longitudinal axis between a first coupling end and a second coupling end. The first adapter is arranged to be at least partially received within the opening proximate the first coupling end. The first adapter extends between a first adapter first face and a first adapter second face. The first adapter defines a first adapter post and a first adapter hole. The first adapter post that extends from the first adapter first face. The first adapter hole that extends from the first adapter first face towards the first adapter second face.