Nested Rail Drivetrain Coupling Assembly for Tight Axial Space
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Solution Overview
Problem
Existing drive train arrangements for rail vehicles require a large installation space due to the use of intermediate shafts, which is not always available, especially in rail vehicles.
Innovation Solution
A series circuit of compensating couplings is designed using disk-shaped coupling bodies and an intermediate body, where the coupling bodies are connected via intermeshed studs and recesses, allowing for rotational movement transmission without the need for an intermediate shaft, thus reducing the axial installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If an intermediate shaft is used to connect two couplings in series, then the desired stiffness and coupling travel are achieved, but the installation space requirement increases significantly
Solution Approach 1:
The patent applies nesting by placing the intermediate coupling body inside the first coupling body and the second coupling body inside the intermediate coupling body, creating a nested configuration where multiple coupling components occupy overlapping spatial volumes. This allows the series circuit of three couplings to be arranged in a compact axial space, resolving the contradiction between achieving desired coupling stiffness through series arrangement and minimizing installation space requirements.
Solution Approach 2:
The patent transitions from a linear axial arrangement of couplings to a nested radial arrangement, effectively utilizing the radial dimension to reduce axial length. By arranging coupling bodies concentrically along the axial direction with intermediate coupling bodies positioned radially inside outer coupling bodies, the design achieves the required series coupling configuration while dramatically reducing the overall axial installation space.
2Power
If an intermediate shaft is used to transmit rotational movements between drive sides, then torque transmission is achieved, but the weight of the drive train increases
Solution Approach 1:
The patent employs flexible membrane elements as coupling elements that can transmit torque while accommodating relative movements between drive sides. These thin-film membrane couplings replace heavy rigid intermediate shafts, achieving the required power transmission function with significantly reduced weight while maintaining the necessary flexibility for coupling travel and vibration damping.
Solution Approach 2:
The patent utilizes composite material structures in the coupling bodies and membrane elements, combining materials with different properties to achieve optimal strength-to-weight ratios. This allows the drive train components to transmit required torques while minimizing weight, resolving the contradiction between power transmission capability and drive train weight.
3Reliability
If traditional coupling arrangements are used, then reliable torque transmission is achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the coupling system into modular segments - first coupling body, intermediate coupling body, and second coupling body - that can be manufactured separately and assembled. This segmentation allows each component to be optimized for its specific function and manufactured using appropriate processes, reducing overall manufacturing complexity while maintaining reliable torque transmission through the series arrangement of specialized coupling elements.
Data Source
AI summary
An assembly for connecting two drive sides of a drive train of a rail vehicle includes a first drive side having a disc-shaped first coupling body at one end, a second drive side having a disc-shaped second coupling body at one end and a disc-shaped intermediate body disposed between the first coupling body and the second coupling body. The intermediate body is coupled to both the first coupling body and the second coupling body in such a way that a rotational movement of one of the two drive sides is transmitted to the other drive side through the coupled body.