Keyless Generator Shaft Coupling for High-Ratio Pulley Drives
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Solution Overview
Problem
Existing engine-driven power systems face challenges in efficiently adjusting rotational speeds between components like generators and air compressors, leading to increased complexity, noise, and difficulty in achieving large speed ratios using conventional belt systems.
Innovation Solution
A keyless coupling arrangement featuring a generator shaft with a tapered surface, a sleeve coupler with complementary tapered surfaces, and pulleys with integrated clutch mechanisms, allowing for secure attachment and efficient transfer of rotational forces without the need for keyed shafts, thereby enabling non-synchronous operation and reducing assembly and disassembly complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional belt systems are used to adjust rotational speed, then speed adjustment capability is provided, but device complexity and noise increase
Solution Approach 1:
The patent extracts and eliminates the keyed shaft component from the generator assembly, using a keyless coupling arrangement where the pulley is directly coupled to the generator shaft through a tapered interface. This removal of the key component simplifies the overall drive system structure while maintaining the ability to adjust rotational speeds through the belt and pulley mechanism.
Solution Approach 2:
The patent merges the pulley and coupling functions into a single integrated component. The pulley is directly coupled to the generator shaft without an intermediate keyed connection, combining the belt drive function and the shaft coupling function into one unified assembly, thereby reducing complexity and noise.
2Strength
If keyed shafts are used for secure attachment, then mechanical strength is improved, but assembly and disassembly complexity increases
Solution Approach 1:
The patent removes the key and keyed shaft components from the assembly, eliminating the complex keyway machining and key installation/removal processes. The keyless coupling uses a tapered interface with a drawbolt mechanism that allows for simpler assembly and disassembly operations while maintaining secure mechanical attachment.
Solution Approach 2:
The patent introduces a drawbolt as an intermediary component that enables easy assembly and disassembly. The drawbolt passes through the pulley and generator shaft, allowing the operator to easily assemble by tightening the drawbolt and disassemble by loosening it, without requiring complex key installation or special tools.
3Reliability
If conventional coupling methods are used, then secure attachment is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent eliminates the key, keyways, and associated machining operations from the manufacturing process. The keyless coupling uses a tapered interface that can be manufactured more simply, reducing machining complexity and manufacturing costs while maintaining secure attachment through the tapered fit and drawbolt retention.
Solution Approach 2:
Instead of using a key to prevent relative motion between the pulley and shaft, the patent inverts the approach by using a tapered interface where the pulley is drawn tightly against the shaft. The security of attachment comes from the friction and mechanical interference of the tapered surfaces rather than from a key, simplifying manufacturing.
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 solution allows for a compact, cost-effective, and robust power system that efficiently adjusts rotational speeds, reduces noise and vibration, and simplifies assembly and maintenance by eliminating the need for keyed shafts, while maintaining high power output and flexibility in speed ratios.
Implementation Method 1
the generator shaft is shaped at an end to define a first tapered surface; a sleeve coupler shaped to define a bore with a second tapered surface
Implementation Method 2
the first tapered surface and the second tapered surface are complimentary to one another
Implementation Method 3
the second pulley is configured to transfer a rotational force to the generator shaft and to the sleeve coupler
Implementation Method 4
the second pulley engages the sleeve coupler via a protruding flange
Data Source
AI summary
Described is a generator for an engine-driven power system. The generator having a generator shaft, a sleeve coupler, a first pulley, and a second pulley. The generator shaft, which is shaped at an end to define a first tapered surface, rotates a rotor relative to a stator. The sleeve coupler is shaped to define a bore with a second tapered surface. The bore receives the end of the generator shaft. The first pulley has a center hole to receive the sleeve coupler. The second pulley shares an axis of rotation with the first pulley and transfers a rotational force to the generator shaft and to the sleeve coupler.