Laterally Engaging Drive Couplers for Axial Misalignment

Solution Overview

Problem

Traditional torque transmission mechanisms are not well-suited for applications where machines need to transfer torque laterally between mobile and stationary units, especially under conditions of axial misalignment, as they require precise axial alignment which is difficult to maintain in such scenarios.

Innovation Solution

A torque transfer apparatus and method that allows for lateral engagement between drive and driven couplers with orthogonal alignment, using a compliance mechanism and matched mating members to adapt to misalignment and ensure stable coupling, and includes features for collision mitigation and second-order coaxial alignment correction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional axial engagement mechanisms are used for torque transmission, then reliable torque transfer is achieved, but precise axial alignment is required which is difficult to maintain in mobile-stationary unit applications

Engineering Contradiction:

Improvetorque transfer reliabilityVSAvoidaxial alignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent inverts the traditional engagement approach by using lateral engagement instead of axial engagement. The drive coupler and driven coupler engage perpendicular to the driven axis, eliminating the need for precise axial alignment while maintaining reliable torque transfer through the lateral engagement geometry.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the engagement parameter from axial direction to lateral direction. By rotating the engagement direction by 90 degrees relative to the driven axis, the system accommodates axial misalignment while preserving torque transmission reliability through the altered engagement geometry.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If lateral engagement is used to accommodate misalignment, then axial alignment tolerance is improved, but the engagement direction becomes orthogonal to the driven axis requiring new mechanism designs

Engineering Contradiction:

Improvemisalignment accommodationVSAvoidcoupling mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent inverts the traditional engagement approach by using lateral engagement instead of axial engagement. The drive coupler and driven coupler engage perpendicular to the driven axis, eliminating the need for precise axial alignment while maintaining reliable torque transfer through the lateral engagement geometry.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If axial actuation is used for coupling, then simple engagement motion is achieved, but repeatable and reliable operation is difficult under lateral movement conditions

Engineering Contradiction:

Improveengagement motion simplicityVSAvoidcoupling reliability under lateral movement

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent inverts the traditional engagement approach by using lateral engagement instead of axial engagement. The drive coupler and driven coupler engage perpendicular to the driven axis, eliminating the need for precise axial alignment while maintaining reliable torque transfer through the lateral engagement geometry.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS9982722B2Torque transfer in laterally engaging drive couplers exhibiting axial misalignment with driven couplers

Publication Date: 2018.05.29 TESLA INC

AI summary

The present invention relates to transferring torque between a first unit, which is typically a mobile machine or a robot, and a second unit, which is typically a fixed or stationary machine. The units are arranged such that a drive coupler of the first unit designed for delivering torque about a drive axis can engage the driven coupler, which belongs to the second unit and has a driven axis, along an engagement direction that is nearly perpendicular to the direction of the driven axis. A lateral displacement mechanism in provided is the first unit to achieve a first-order coaxial alignment between the drive and driven axes. Additional measures such as compliance mechanisms are provided for improving engagement, coupling and reducing the level of axial misalignment in the apparatus and methods of the invention.