Universal Joint Shaft With Integrated Generator and Planetary Gear
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Solution Overview
Problem
Existing universal joint shafts for agricultural machines do not efficiently integrate electrical power generation without disrupting mechanical torque transmission, requiring additional space and components.
Innovation Solution
A compact universal joint shaft design incorporating a generator and power electronics within the housing, utilizing a planetary gear to increase speed and maintain mechanical power transmission, with a torque support and air-cooling for efficient energy conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a generator is integrated into the universal joint shaft, then electrical power generation is enabled, but the device complexity increases
Solution Approach 1:
The generator is integrated directly into the universal joint shaft housing, merging two previously separate systems (mechanical torque transmission and electrical power generation) into a single compact unit. This eliminates the need for separate mounting of the generator and reduces overall system complexity despite adding functional capability.
Solution Approach 2:
The universal joint shaft is transformed into a multi-functional component that simultaneously performs mechanical torque transmission between PTO shaft and implement, and electrical power generation through the integrated generator. This multi-functionality resolves the contradiction by enabling power generation without requiring a completely separate system.
2Adaptability or versatility
If a generator is added to the universal joint shaft, then electrical power is generated, but the installation space requirement increases
Solution Approach 1:
The generator is nested within the existing housing of the universal joint shaft, utilizing the available internal space rather than requiring additional external mounting space. This nesting approach allows the generator to be accommodated without significantly increasing the overall volume of the universal joint shaft assembly.
Solution Approach 2:
By merging the generator with the universal joint shaft housing, the patent eliminates the need for separate mounting space. The generator shares the housing space with the universal joint mechanism, thereby resolving the space requirement issue while enabling power generation.
3Speed
If a planetary gear transmission is used to increase speed, then the speed of the connecting hub is increased, but the device complexity increases
Solution Approach 1:
The planetary gear transmission acts as an intermediary mechanism between the connecting hub and the rotor. It provides speed multiplication while maintaining a compact structure, resolving the contradiction by achieving high speed increase without proportionally increasing overall system complexity.
Solution Approach 2:
The planetary gear system is self-contained within the generator assembly, utilizing the existing rotational motion of the universal joint shaft to drive the transmission. The system serves itself by converting the available mechanical energy into increased rotational speed for the rotor without requiring external intervention or additional complex control mechanisms.
4Volume of moving object
If power electronics are integrated into the housing, then the design becomes more compact, but the heat dissipation challenge increases
Solution Approach 1:
The patent converts the harmful heat generated by power electronics into a beneficial cooling opportunity by integrating air cooling pathways through the housing. The housing structure itself becomes a heat dissipation system, using ambient air flow to remove heat from power electronics, thereby resolving the contradiction between compactness and heat management.
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
Enables efficient electrical power generation without interrupting mechanical torque transmission, providing a compact and integrated solution with enhanced speed and cooling capabilities.
Implementation Method 1
The transmission can be a planetary gear. Here, a ring gear of the planetary gear can be connected to the housing, a sun gear of the planetary gear can be connected to the rotor, and a planet carrier of the planetary gear can be connected to the connecting hub in a rotationally fixed manner
Implementation Method 2
A generator is accommodated in said housing and has a stator rigidly connected to the housing and arranged coaxially to the connecting hub, and has a rotor rotatably mounted relative to the housing, wherein the rotor is drivingly connected to the connecting hub via a transmission
Implementation Method 3
The compact design of the universal joint shaft can be complemented by the generator and/or power electronics being air-cooled via the housing
Data Source
AI summary
A universal joint shaft can be provided for transmitting torque between a power take-off shaft of a driving agricultural machine and a drive journal of an agricultural implement to be driven. The universal joint shaft comprisesa first joint with a first inner joint member and a first outer joint member, which are pivotably and torque-transmittingly connected to each other, a second joint, with a second inner joint member and a second outer joint member, which are pivotably and torque-transmittingly connected to each other, a connecting shaft, via which the first inner joint member and the second inner joint member are connected to each other in a rotationally fixed manner, anda connecting hub which is rigidly connected to the first outer joint member and has connecting means for connecting the connecting hub to a shaft in a rotationally fixed manner, a housing in which the connecting hub is accommodated and rotatably mounted, and a generator accommodated in the housing, said generator has a stator rigidly connected to the housing and arranged coaxially to the connecting hub, and said generator further has a rotor rotatably mounted relative to the housing, wherein the rotor is drivingly connected to the connecting hub via a transmission.