Flywheel Crankshaft Meshing for High Torque Transmission
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Solution Overview
Problem
Existing systems that use a crankshaft journal bearing to support a rotor in a single bearing generator face limitations in transmitting high torque at high rotational speeds due to the bearing's surface speed limitations, which restrict the crankshaft's diameter and rotational speed, making them mutually exclusive.
Innovation Solution
A combination that includes a flywheel with protrusions or teeth configured to mesh with a crankshaft, using a bearing within a power source to support the flywheel and crankshaft, and employing threaded fasteners to maintain a meshed configuration of teeth, allowing torque transmission without damaging the bearing at high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a crankshaft journal bearing is used to support the crankshaft end, then bending movement of the crankshaft is reduced, but the surface speed of the crankshaft is limited which prevents transmission of large torque at high rotational speeds
Solution Approach 1:
A flywheel is introduced as an intermediary component between the crankshaft and the rotor. The flywheel receives torque from the crankshaft via meshing teeth and transmits it to the rotor, allowing the crankshaft to operate at high speeds without directly driving the rotor, thus resolving the surface speed limitation imposed by the journal bearing.
Solution Approach 2:
The power transmission function is segmented into two stages: first, the crankshaft drives the flywheel through meshing teeth at high speed; second, the flywheel drives the rotor through direct connection. This segmentation allows each component to operate within its optimal speed range, with the flywheel acting as a speed-matching intermediary.
2Strength
If the diameter of the crankshaft is increased to transmit large amounts of torque, then torque transmission capability is improved, but the rotational speed must be reduced to maintain constant surface speed
Solution Approach 1:
The flywheel serves as a mediator that decouples the torque transmission function from the speed limitation. The crankshaft can be optimized for high-speed operation with appropriate diameter, while the flywheel-transmission system handles the torque multiplication and transmission to the rotor, allowing both high torque and high speed to be achieved simultaneously.
3Strength
If the number of bolts is increased to improve the strength of the connection between crankshaft and flywheel, then torque transmission is improved, but the device complexity increases
Solution Approach 1:
The traditional bolted flange connection is replaced with a meshing teeth mechanism. Instead of relying on multiple bolts to transmit torque through friction and clamping force, the involute teeth of the crankshaft and flywheel engage to directly transmit torque through mechanical engagement, providing superior torque transmission with fewer fasteners and reduced complexity.
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
This configuration reduces bending stresses in the crankshaft, enables the transmission of large amounts of torque at high rotational speeds without damaging the bearing, and reduces maintenance costs by minimizing orbiting and vibrating effects.
Implementation Method 1
a bearing, which may be situated at least partially within the power source. The bearing may be configured to support and at least partially house the flywheel
Implementation Method 2
The plurality of crankshaft protrusions may be shaped to mesh with the plurality of flywheel protrusions
Data Source
AI summary
A combination for use in supporting and rotatably driving a mass is disclosed. The combination may have a power source. The combination may also have a flywheel, which may be configured to connect with and rotatably drive the mass. The flywheel may have a flywheel end, which may have a plurality of flywheel protrusions. Additionally, the combination may have a bearing, which may be situated at least partially within the power source. The bearing may be configured to support and at least partially house the flywheel. In addition, the combination may have a crankshaft, which may be shaped to connect with and rotatably drive the flywheel. The crankshaft may have a crankshaft end, which may have a plurality of crankshaft protrusions. The plurality of crankshaft protrusions may be shaped to mesh with the plurality of flywheel protrusions.