Motor Coupler Assembly With Involute Support for Quiet Reliable Coupling
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Solution Overview
Problem
Conventional couplers manufactured using forging methods face challenges in achieving desired shapes and ensuring coupling force due to twisting during manufacturing, and they generate noise due to surface contact when motors are driven.
Innovation Solution
A coupler is manufactured using a combination of forging and injection methods, featuring an inner insertion part with a polygonal structure, projection parts, and an outer support part with involute curves to enhance coupling force and reduce noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional forging method is used to manufacture the coupler, then the manufacturing process is simple, but it is difficult to implement a precise shape and ensure coupling force
Solution Approach 1:
The coupler is divided into two separate parts: an inner insertion part manufactured by forging and an outer support part manufactured by injection molding. This segmentation allows each part to be optimized for its specific manufacturing process, achieving precise shapes that would be impossible with a single forging method while maintaining manufacturing efficiency.
Solution Approach 2:
The patent combines two different manufacturing methods (forging and injection molding) to create a composite coupler structure. The inner insertion part uses forging for strength, while the outer support part uses injection molding for precise shape control, merging the advantages of both processes to overcome the limitations of using either method alone.
2Reliability
If the coupler location is twisted during manufacturing, then the manufacturing process is flexible, but the coupling force with the shaft cannot be ensured
Solution Approach 1:
The inner insertion part is pre-manufactured with precise positioning features through forging, and the outer support part is subsequently molded around it with injection material. This preliminary action ensures that the coupling geometry is established before final assembly, preventing twisting issues while maintaining manufacturing efficiency.
Solution Approach 2:
The inner insertion part has localized precise geometric features (such as keyed portions or splines) that are critical for coupling reliability, while the outer support part provides general structural support. This local quality approach ensures that the critical coupling interface maintains high precision without requiring the entire manufacturing process to be equally complex.
3Object-affected harmful factors
If surface contact between the coupler and other objects is used, then the structure is simple, but noise occurs when the motor is driven
Solution Approach 1:
The outer support part features a curved engagement surface that contacts the inner insertion part. This curvature distributes contact forces more evenly and reduces impact noise compared to flat surface contact, while maintaining a relatively simple overall structure. The curved geometry also allows for smoother relative motion between components.
Data Source
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AI summary
The present invention provides a coupler comprising: an inner insertion part including a through-hole; and an outer support part for encompassing the outside of the inner insertion part, wherein the inner insertion part includes a connection groove through which the outer support part passes, the outer support part includes at least one projection part protruding in the center direction of the through-hole, and the projection part includes a groove part.