Layered Lamination Package for Compact High-Torque Couplings
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Solution Overview
Problem
Existing multi-plate couplings face challenges in achieving high mechanical performance, space-saving design, reliability, long life, and cost-effective manufacturing while maintaining high torque transmission and low misalignment capabilities.
Innovation Solution
A package of laminations comprising ring-shaped lamella segments with cutouts that accommodate sleeves, allowing for a compact, scalable, and cost-effective construction with a high degree of mechanical stress resistance, achieved through a layered arrangement and efficient manufacturing method using a separation pattern on a blank sheet of metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-plate couplings are designed for high torque transmission, then mechanical performance capability is improved, but the device occupies more space
Solution Approach 1:
The coupling is divided into multiple individual lamella segments that can be stacked in layers. Each segment is a separate component with cutouts for sleeves, allowing the torque transmission capability to be increased by adding more segments rather than increasing the size of individual segments. This segmentation enables high torque transmission in a compact, space-efficient manner.
Solution Approach 2:
The lamella segments are arranged in a layered configuration along the axial dimension, allowing the coupling to achieve high torque transmission capacity without increasing the radial or circumferential dimensions. By stacking segments in the axial direction, the device transmits higher torque while maintaining a compact overall footprint.
2Power
If multi-plate couplings are designed for high torque transmission, then mechanical performance capability is improved, but manufacturing complexity increases
Solution Approach 1:
The coupling is divided into multiple individual lamella segments that can be stacked in layers. Each segment is a separate component with cutouts for sleeves, allowing the torque transmission capability to be increased by adding more segments rather than increasing the size of individual segments. This segmentation enables high torque transmission in a compact, space-efficient manner.
Solution Approach 2:
The lamella segments are arranged in a layered configuration along the axial dimension, allowing the coupling to achieve high torque transmission capacity without increasing the radial or circumferential dimensions. By stacking segments in the axial direction, the device transmits higher torque while maintaining a compact overall footprint.
3Strength
If lamella segments are connected via multiple sleeves, then constructional freedom and mechanical stress resistance are improved, but device complexity increases
Solution Approach 1:
The sleeves serve multiple functions: they connect adjacent lamella segments together, provide alignment features through the cutouts, and enable the layered stacking configuration. This multi-functionality allows the same component (sleeve) to achieve both structural integrity and geometric arrangement, reducing the need for additional specialized components.
Solution Approach 2:
The coupling is divided into multiple individual lamella segments that can be stacked in layers. Each segment is a separate component with cutouts for sleeves, allowing the torque transmission capability to be increased by adding more segments rather than increasing the size of individual segments. This segmentation enables high torque transmission in a compact, space-efficient manner.
Data Source
AI summary
A package of laminations includes a plurality of lamella segments, which are arranged in layers and embodied to be connected together as ring segments. Each of the lamella segments has a plurality of cutouts and at least one of the lamella segments has at least three cutouts. The lamella segments are interconnected via sleeves. A method for manufacturing a package of laminations, a multi-plate coupling employing the package of laminations and an industrial application using the package of laminations are also described.