Floating Load Ring Assembly for Bellows Load Distribution
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Solution Overview
Problem
Existing flexible couplings require different end components for load-supporting and non-load supporting configurations, making it impractical to add load rings to non-load supporting couplings without redesigning existing components, leading to increased inventory and manufacturing complexity.
Innovation Solution
A floating load ring is integrated between the braid and bellows in flexible couplings, held in place by existing components without welding, allowing for conversion of non-load supporting couplings to load-supporting ones without modifying existing designs, using materials like solid metal, compressed steel mesh wires, or polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different end components are used for load-supporting and non-load supporting configurations, then load protection is achieved, but device complexity and inventory requirements increase
Solution Approach 1:
The end component is designed to perform multiple functions: it serves as both the structural endpoint and the load-bearing element through the integrated floating load ring. This single component design eliminates the need for different end components in load-supporting versus non-load supporting configurations, reducing inventory requirements while maintaining load protection capabilities.
Solution Approach 2:
The floating load ring is merged with the end component assembly, combining the load-distributing function with the existing structural elements. This integration allows the same end component to accommodate both load-supporting and non-load supporting applications without requiring separate designs.
2Reliability
If load rings are added to non-load supporting couplings, then load distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The floating load ring is designed to be self-positioning and self-retaining within the end component assembly. It floats freely and is held in place by the natural geometry of the surrounding components without requiring additional attachment steps, welding, or specialized manufacturing processes. This self-service design allows load rings to be added to existing non-load supporting couplings without increasing manufacturing complexity.
3Duration of action of stationary object
If floating load ring is used, then wear on bellows is reduced, but component count increases
Solution Approach 1:
The floating load ring acts as an intermediary element between the external load and the bellows structure. It distributes concentrated loads across a broader area, preventing direct contact between high-stress points and the bellows surface. This intermediary function protects the bellows from wear and deformation while the ring itself absorbs the mechanical stress.
Solution Approach 2:
The floating load ring is designed as a simple, inexpensive component that can be easily manufactured from common materials. Rather than designing complex, expensive bellows protection systems, a simple load-distributing ring provides effective protection at low cost, making it economically worthwhile to include as a separate component.
Data Source
AI summary
A free-floating load ring for assembly into a flexible coupling having a convoluted bellows and a surrounding mesh sleeve, the ring captured by the sleeve at an end of the coupling and spacing the sleeve from the bellows when forces are applied to the coupling. Various rings can be added to existing non-load supporting or flexible couplings having no previous rings. The load ring is retained in place by engagement of coupling components with the ring without physical connection of the ring to any coupling component.