Mechanical Connector Structure for High Torque and Bending Fatigue
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Solution Overview
Problem
Existing mechanical connectors, such as those in the Merlin™ family, face limitations in accurately controlling and handling high torsional loads due to their design, which can lead to difficulties in managing torque transfer effectively.
Innovation Solution
The introduction of structural features like dog-clutch teeth, fitted pins, keys, and spline systems, combined with zero-pitch angle threads, allows for enhanced torque transfer capabilities while maintaining high static and fatigue bending load capacities, enabling the connectors to handle high torsional loads through optimized design modifications or new constructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional Merlin family connector designs are used, then high static and fatigue bending load capacities are achieved, but torsional load capacities are limited and difficult to control accurately
Solution Approach 1:
The connector is divided into functional segments: a pin component, a box component, and an intermediate component. Each segment serves specific functions - the pin and box provide the basic connection and bending load capacity, while the intermediate component with dog-clutch teeth, fitted pins, keys, or splines provides the enhanced torsional load capacity. This segmentation allows optimization of each component for its specific function without compromising the overall connector design.
Solution Approach 2:
An intermediate component is introduced between the pin and box to mediate torque transfer. This intermediate component contains structural features such as dog-clutch teeth, fitted pins, keys, or splines that engage with corresponding features on the pin and box. This intermediary element enables controlled and enhanced torsional load capacity while maintaining the original pin-box connection design for bending loads.
2Reliability
If structural features like dog-clutch teeth, fitted pins, keys, and splines are added to enhance torque transfer, then torsional load capacity and torque transfer efficiency are improved, but device complexity increases
Solution Approach 1:
The intermediate component is designed to provide multiple torque transfer mechanisms (dog-clutch teeth, fitted pins, keys, or splines) that can be selected based on specific application requirements. This universal approach allows the same basic intermediate component design to serve multiple torque transfer functions, reducing the need for entirely different connector designs for different torsional load requirements.
Solution Approach 2:
Specific structural features are placed at specific locations within the intermediate component based on local stress and torque transfer requirements. For example, dog-clutch teeth may be positioned at the interface with the pin, while fitted pins or keys are positioned to engage with the box. This localized placement of structural features optimizes torque transfer efficiency while minimizing unnecessary complexity in regions where such features are not needed.
Data Source
AI summary
This invention builds up on technical features and on the industry experience with the use of Merlin™ family connectors. In addition to friction, structural means utilized in order to transfer high torsional loads include: dog-clutch teeth, shear pins, keys, splines and interlocked thread systems, all used in isolation or in arbitrary combinations. Static and fatigue bending load capacities of the connectors remain high, while the axial load capacities may or may not be high, depending on the design requirements. Connectors according to this invention can be built as new, carefully optimized designs. In some cases upgrading existing Merlin™ family connector designs to increase they torque transfer capacities may be also feasible.