Keyless Generator Shaft Coupling for Variable Speed Drive
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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 non-synchronous 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 and adjustable rotational force transfer without the need for keyed shafts, thereby simplifying assembly and disassembly.
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 system complexity and noise increase
Solution Approach 1:
The patent extracts and eliminates the belt system from the power transmission mechanism, replacing it with a direct keyless coupling between engine and generator. This removes the intermediate belt transmission components while maintaining speed adjustment capability through alternative means, thereby reducing system complexity and noise.
Solution Approach 2:
The keyless coupling system integrates multiple functions into a single mechanism: it provides both mechanical coupling and rotational speed adjustment capability. The clutch mechanism within the keyless coupling allows for variable speed operation without requiring separate belt transmission systems, achieving multi-functionality that reduces overall system complexity.
2Reliability
If keyed shafts are used for coupling, then secure mechanical connection is achieved, but assembly and disassembly complexity increases
Solution Approach 1:
The patent removes the key and keyway components from the traditional keyed shaft coupling, replacing them with a keyless interface. This extraction of the keying mechanism eliminates the complexity of fitting and removing keys while maintaining secure mechanical connection through alternative coupling features such as interference fits or form-fit interfaces.
Solution Approach 2:
Instead of using a key inserted into keyways to prevent relative rotation, the invention inverts the approach by using a keyless interface where the coupling itself provides both connection and rotational synchronization. The clutch mechanism within the keyless coupling handles rotational control without requiring traditional keying, simplifying assembly and disassembly operations.
3Adaptability or versatility
If belt systems are used for non-synchronous speed ratios, then speed matching is possible, but noise and vibration increase
Solution Approach 1:
The patent eliminates the belt transmission system that generates noise and vibration during non-synchronous operation. By replacing the belt system with a direct keyless coupling integrated with a clutch mechanism, the invention removes the source of harmful noise and vibration while maintaining the capability to operate at non-synchronous speed ratios.
Solution Approach 2:
The invention replaces the mechanical belt transmission system with an integrated keyless coupling and clutch mechanism. This substitution eliminates the intermediate belt and pulley system that generates noise and vibration, using instead a direct mechanical coupling with controlled slippage or variable ratio capability through the clutch mechanism.
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 enables efficient adjustment of rotational speeds, reduces noise and vibration, and simplifies maintenance by eliminating the complexity of keyed shafts, resulting in a more robust, cost-effective, and easier-to-assemble power system.
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
a second pulley configured to transfer a rotational force to the generator shaft and to the sleeve coupler
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.