Folded Torque Coupling for Misalignment and Low Friction
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Solution Overview
Problem
Existing couplings face challenges in achieving low friction, dynamic stress resistance, and ease of assembly while accommodating misalignment between rotary components, particularly in applications where weight minimization and cost-effectiveness are critical.
Innovation Solution
A coupling design featuring a female member, a male member, and a coupling member with an alternating sequence of outer and inner folds, where the folds are connected to the female and male members respectively, allowing for compression and torque transfer while accommodating misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional coupling designs are used to transfer torque between misaligned rotary components, then torque transfer capability is maintained, but friction and dynamic stress increase
Solution Approach 1:
The coupling member is segmented into multiple folds (outer folds and inner folds) that can independently deform and articulate. This segmentation allows each fold to accommodate misalignment through controlled deformation, reducing friction between the coupling and the shafts while distributing dynamic stresses across multiple segments rather than concentrating them in a single rigid structure.
Solution Approach 2:
The coupling member transitions from a rigid structure to a dynamic, flexible structure capable of real-time adaptation. The folds are designed to dynamically adjust their configuration based on the degree and direction of misalignment, allowing the coupling to maintain optimal contact with the shafts while minimizing friction and absorbing dynamic stresses through elastic deformation.
2Ease of operation
If coupling designs accommodate misalignment between rotary components, then ease of assembly improves, but manufacturing complexity increases
Solution Approach 1:
The coupling member is divided into multiple identical or similar folds that can be manufactured using standardized processes. This segmentation into repeatable units simplifies the manufacturing of individual components while the overall assembly provides misalignment accommodation, effectively distributing the manufacturing complexity across multiple simple, identical elements rather than one complex custom component.
Solution Approach 2:
The coupling design utilizes parameter changes in the fold geometry (such as fold angle, amplitude, and spacing) to achieve misalignment accommodation without fundamentally changing the manufacturing process. By adjusting these geometric parameters within standard manufacturing capabilities, the coupling provides flexibility for assembly while remaining compatible with conventional manufacturing methods.
3Power
If rigid coupling structures are used for torque transfer, then torque transmission efficiency is maintained, but friction increases under misalignment conditions
Solution Approach 1:
The coupling member employs dynamic folds that can adapt their configuration in real-time based on operating conditions and misalignment degree. This dynamic capability allows the coupling to maintain effective torque transmission through controlled deformation of the folds, ensuring that power is efficiently transferred while the flexible structure minimizes friction by avoiding rigid contact under misalignment.
Solution Approach 2:
The coupling member utilizes a flexible, thin-walled structure with folds that can bend and articulate without significant energy loss. This flexible shell design allows the coupling to conform to misaligned shaft positions while maintaining structural integrity for torque transfer, reducing friction compared to rigid structures that would require forceful contact to transmit power under misalignment.
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
The coupling effectively transfers torque while minimizing friction and dynamic stress, accommodates misalignment through deformation, and offers improved manufacturability and assembly ease, making it suitable for weight-sensitive and cost-constrained applications.
Implementation Method 1
the inner folds being circumferentially offset from the outer folds in a given angular direction operable to subject the coupling member to compression when transmitting torque
Data Source
AI summary
The coupling can have a female member having a plurality of female member connections circumferentially arranged along a radially inner face; a male member having a plurality of male member connections circumferentially arranged along a radially outer face; and a coupling member extending annularly around the axis, the coupling member having a strip, the strip having, circumferentially relative the axis, an alternating sequence of outer folds and inner folds, the outer folds connected to the female member via respective ones of the female member connections, the inner folds connected to the male member via respective ones of the male member connections, the inner folds being circumferentially offset from the outer folds in a given angular direction.