Granular-Damped Encoder Coupling for Resonance Vibration Peaks

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Solution Overview

Problem

Existing clutch systems connecting sensors to electrical machines experience vibration peaks due to resonance, limiting operational dynamics and requiring either sub-resonance operation or power-consuming filters to mitigate these issues.

Innovation Solution

A shaft end piece coupling with granular material-filled cavities and a torque transmission element, preferably made of plastic, is used to dampen vibrations and shocks, allowing operation beyond resonance without filters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the electric machine operates at resonance frequency, then the frequency range is extended, but vibration amplification occurs

Engineering Contradiction:

Improvefrequency rangeVSAvoidvibration amplification

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful vibration amplification at resonance into a beneficial damping effect by introducing granular material into cavities. The granular material absorbs and dissipates vibrational energy through friction and collision between particles, transforming the harmful resonance phenomenon into a controlled energy dissipation mechanism that protects the system while allowing operation at resonance frequencies.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent employs cavities filled with granular material, creating a porous-like structure within the coupling component. This porous configuration allows the granular material to move freely and dissipate vibrational energy effectively, while maintaining the structural integrity of the coupling. The cavities are strategically designed to optimize the damping effect without compromising mechanical strength.

Inventive Principle:

Principle #31Porous materials

2Object-affected harmful factors

If electronic filters are used to prevent resonance excitation, then vibration is reduced, but controller processing power is reduced

Engineering Contradiction:

ImprovevibrationVSAvoidcontroller processing power

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

The patent replaces the electronic filtering approach with a mechanical damping solution. Instead of using electronic filters that consume controller processing power, the invention uses a passively operating mechanical damping system with granular material that physically absorbs vibrations. This substitution eliminates the need for complex electronic control and processing, reducing the burden on the controller while effectively mitigating vibrations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the coupling and sensor inertia create an oscillating system, then the system is formed, but vibration peaks at resonance occur

Engineering Contradiction:

Improvesystem formationVSAvoidvibration peaks

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces granular material as an intermediary element within the coupling system. This intermediary substance acts as a mediator between the oscillating components, absorbing and dissipating the vibrational energy that would otherwise cause harmful resonance peaks. The granular material serves as a buffer that maintains system reliability while mitigating the harmful effects of oscillation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution effectively damps vibration peaks at resonance, enabling extended frequency range operation of electrical machines without the need for electronic filters, while maintaining structural integrity using steel or steel powder components.

Implementation Method 1

the granular material located in the cavities of the shaft ends dampens shocks and vibrations

Methodology Applied

Scientific EffectVibration damping: Damping

Implementation Method 2

The torque transmission element is inserted between the end of the encoder and the end of the machine shaft. This reduces friction

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 3

a torque transmission element, wherein, for coupling the encoder shaft with the machine shaft, the encoder shaft end piece is arranged opposite the machine shaft end piece and the torque transmission element is arranged between the encoder shaft end piece and the machine shaft end piece

Methodology Applied

Scientific EffectTorque transmission: Torque

Data Source

PatentEP3574225B1Coupling elements with vibration damping

Publication Date: 2023.02.01 SIEMENS AG

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AI summary

The invention relates to a coupling for connection of an encoder to an electrical machine, wherein the coupling comprises an encoder shaft end piece, which can be coupled to an encoder shaft, and a machine shaft end piece, which can be coupled to a machine shaft, wherein at least one end piece has at least one carrier. The carriers have a cavity filled with granular material, preferably steel powder, which effects a dampening of vibrations and impacts. The invention further relates to a suitable production method by means of additive production and to the use of such a coupling.