Gear Coupling with Insulating Intermediate Tube
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Solution Overview
Problem
Conventional gear couplings face limitations in transmitting high torque while maintaining electrical insulation and protecting against mechanical damage, particularly in environments with high risk of debris.
Innovation Solution
A gear coupling design featuring an intermediate tube made of electrically insulating fiber-reinforced plastic that connects two coupling sections, providing both electrical insulation and mechanical protection, with detachable connections and shaft-hub arrangements for space efficiency and misalignment compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional insulating components (screw sleeves and washers made of plastic or rubber) are used, then electrical insulation is provided, but the torque transmission capability is limited
Solution Approach 1:
The intermediate tube is made of fiber-reinforced plastic (GRP or CFRP), combining the electrical insulation properties of plastic with the high mechanical strength of fiber reinforcement. This composite material enables the tube to withstand high torques while maintaining electrical insulation between the two coupling sections.
Solution Approach 2:
The patent changes the material parameters by transitioning from conventional plastic/rubber to fiber-reinforced plastic, thereby increasing the torque transmission capability while preserving the electrical insulation function. The fiber reinforcement significantly enhances the mechanical strength without compromising the insulating properties.
2Ease of manufacture
If the intermediate tube is exposed, then assembly is simplified, but mechanical damage from debris (e.g., stone chips) occurs
Solution Approach 1:
The intermediate tube is nested between the two coupling sections, with each coupling section enclosing the tube on its respective side. This nested arrangement provides mechanical protection to the intermediate tube against debris and damage while maintaining the simple assembly structure.
Solution Approach 2:
The coupling sections are designed to enclose and protect the intermediate tube beforehand, preventing mechanical damage from debris such as stone chips before it can occur during operation, particularly in the railway sector where such damage is common.
3Ease of manufacture
If the coupling section is made as one piece, then manufacturing is simpler, but disassembly requires damaging the intermediate pipe connection
Solution Approach 1:
The coupling section is divided into two detachably connected parts: a first part including the driving toothing and a second part adjoining the intermediate pipe. This segmentation allows the driving teeth to be removed without affecting the intermediate pipe connection, enabling easy disassembly and reassembly while maintaining manufacturing simplicity.
Solution Approach 2:
The driving teeth are extracted as a separate, detachable component from the coupling section. This allows the driving teeth to be removed independently without having to damage or disconnect the intermediate pipe connection, facilitating easy maintenance and repair.
4Volume of moving object
If the gear coupling design is compact, then space is saved, but flexibility for misalignment compensation is reduced
Solution Approach 1:
The coupling sections are designed with hubs that can accommodate angular misalignment between shafts, providing dynamic adaptability. The detachable connection with driving teeth allows the coupling to compensate for misalignments while maintaining a compact overall design, as the toothing engagement can accommodate certain degrees of angular deviation.
Data Source
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Figure 2
AI summary
The invention relates to a gear coupling (10) for connecting an input shaft to an output shaft. Said gear coupling (10) comprises a first coupling portion (11) to be connected to the input shaft and a second coupling portion (12) to be connected to the output shaft. At least one of the two coupling portions (11, 12) has a driver toothing with an internal toothing (35, 45) and an outer toothing (15, 25) engaging therewith. The gear coupling (10) further comprises an intermediate tube (5) which is made of an electrically insulating material and which connects the two coupling portions (11, 12) to each other and electrically insulates them from each other.