Layered Lamella Coupling Structure for High-Torque Compact Assemblies
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Solution Overview
Problem
Slat couplings face challenges in achieving high mechanical performance, particularly in terms of nominal torque, reliability, service life, and economical production, while maintaining a compact design.
Innovation Solution
The slat package features layered ring segments with recesses that form a sleeve, allowing for increased constructive freedom and mechanical stress, enabling a high degree of torque absorption and scalability, with a manufacturing process that uses a shell and separation pattern to efficiently produce slat segments with varying recesses for a lamella package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If slat segments are arranged in a flash-like construction, then the structure is simpler to manufacture, but the mechanical stress resistance and nominal torque are reduced
Solution Approach 1:
The patent transitions from a two-dimensional flash-like construction to a three-dimensional layered arrangement of slat segments. Multiple layers are stacked with offset patterns, creating a compact 3D structure that increases mechanical stress resistance and nominal torque while maintaining manufacturability through standardized segment designs.
Solution Approach 2:
The coupling is divided into multiple identical or similar slat segments that can be manufactured separately and then assembled in a layered configuration. This segmentation allows for simplified individual segment manufacturing while achieving superior overall mechanical properties through the layered assembly architecture.
2Power
If the number of sleeves is increased to improve torque transmission, then the nominal torque increases, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses a limited number of sleeves (typically 3-6) positioned at specific intervals around the coupling, rather than attempting to secure all slat segments at all positions. This partial action approach achieves sufficient torque transmission while avoiding the complexity and cost of using excessive numbers of sleeves.
Solution Approach 2:
The sleeves serve multiple functions: they connect adjacent layers of slat segments, transmit torque between layers, and provide positioning alignment. This multi-functionality reduces the need for additional specialized components, thereby controlling device complexity while maintaining high nominal torque capability.
3Strength
If slat segments are made thicker to increase mechanical strength, then the nominal torque and reliability improve, but the coupling thickness and material usage increase
Solution Approach 1:
Instead of increasing the thickness of individual slat segments in one dimension, the patent distributes the structural strength across multiple thinner layers stacked in the radial direction. This dimensional redistribution maintains or improves mechanical strength while reducing the overall thickness of individual segments and potentially reducing total material usage.
Solution Approach 2:
The layered arrangement of multiple slat segments with offset patterns creates a composite structure where the combined assembly achieves superior mechanical properties compared to a single thick segment. The composite architecture optimizes strength-to-thickness ratio and material efficiency.
4Adaptability or versatility
If the recesses of different slat segments are aligned to allow sleeve passage, then the assembly flexibility increases, but the manufacturing precision requirements increase
Solution Approach 1:
The coupling is segmented into modular slat units with standardized recess patterns. This segmentation allows for flexible assembly configurations while the standardization of recess positions across segments helps control manufacturing precision requirements through repeatability.
Solution Approach 2:
The sleeves act as intermediary elements that accommodate minor misalignments between recesses of different slat segments. The sleeves provide a tolerant interface that allows assembly to proceed even with small variations in recess positioning, thereby maintaining assembly flexibility without requiring extremely tight manufacturing tolerances.
Data Source
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AI summary
The invention relates to a lamella stack (10) comprising a plurality of layered lamella segments (20, 22, 24) configured to connect to one another as ring segments (26). Each lamella segment (20, 22, 24) has a plurality of recesses (28). According to the invention, at least one lamella segment (20) has at least three recesses (28). The invention also relates to a method (100) for manufacturing a lamella stack (10). The method (100) comprises a first step (110) in which a raw sheet (42) is provided. In a second step (120), a separation pattern (46) is determined for a plurality of lamella segments (20, 22, 24). In a subsequent step (130) the majority of the lamellar segments (20, 22, 24) are cut out of the raw sheet (42).According to the invention, the lamellar segments (20, 22, 24) are designed as ring segments (26), each having at least three recesses (28) for receiving a sleeve (30).