Nested Torque Coupling for Compact Motor-Reducer Adaptation
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Solution Overview
Problem
Existing torque transmission couplings between motors and speed reducers require different speed reducers for various motor sizes, leading to increased costs and complexity, and existing intermediate couplings increase overall dimensions and manufacturing costs.
Innovation Solution
A coupling design that maintains the same axial overall dimension as a direct connection, using the same support components, and is manufactured cost-effectively, comprising two coupling elements with recesses and projecting bodies that allow for torque transmission without increasing the distance between the motor and speed reducer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an intermediate coupling is used to connect the motor to the speed reducer, then adaptability to different motor sizes is improved, but the overall dimension and distance between motor and speed reducer increase
Solution Approach 1:
The coupling element is nested within the bearing structure, with the outer cylindrical surface of the coupling element fitting into the bearing's inner cylindrical surface. This nesting arrangement allows the coupling to be compact and integrated within the existing space, preventing increase in overall dimension while maintaining adaptability through different coupling element sizes.
Solution Approach 2:
The invention transitions from axial extension to radial integration by placing the coupling element's torque transmission features (recesses and projecting bodies) in the radial dimension rather than extending axially. This allows the coupling to fit within the same axial envelope as a direct connection while providing intermediate coupling functionality.
2Adaptability or versatility
If an intermediate coupling with special connection profiles is used, then adaptability to different motor sizes is improved, but manufacturing cost increases
Solution Approach 1:
The coupling is segmented into a first coupling element connected to the speed reducer and a second coupling element connected to the motor shaft, with torque transmission through recesses and projecting bodies. This segmentation allows each element to be manufactured separately using standard processes, avoiding the need for expensive custom-machined special profiles while maintaining adaptability through modular design.
Solution Approach 2:
The invention changes the parameter of torque transmission from complex profile geometry to simple geometric features (recesses and projecting bodies) that can be manufactured with standard tolerances. This parameter change maintains the functionality of torque transmission while significantly reducing manufacturing complexity and cost.
3Ease of manufacture
If a direct connection is used between the driving shaft and input shaft, then manufacturing cost is reduced, but adaptability to different motor sizes and damage resistance are worsened
Solution Approach 1:
The coupling element serves multiple functions: it connects different motor sizes to the same speed reducer input shaft, transmits torque through simple geometric features, and provides a replaceable component that protects the speed reducer from damage. This multi-functionality maintains manufacturing simplicity while adding adaptability and protection capabilities.
4Device complexity
If a direct connection is used between the driving shaft and input shaft, then device complexity is reduced, but reliability is worsened due to potential damage propagation
Solution Approach 1:
The coupling element acts as an intermediary component between the motor shaft and speed reducer input shaft. This intermediary provides torque transmission while serving as a protective barrier that can be replaced if damaged, preventing damage propagation to the more expensive speed reducer and thereby improving system reliability.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Coupling (1) for the transmission of the torque between a driving shaft (2) and a driven shaft (3), comprising a first coupling element (4) developing according to a first longitudinal axis (X) between a first end (4a), provided with first rotational constraint means (6) for connecting to the driven shaft (3) so that the first longitudinal axis (X) is coaxial to the axis of the driven shaft (3), and a second end (4b) juxtaposed to the first end (4a) and which defines an end surface (4c) orthogonal to the first longitudinal axis (X) and delimiting the first coupling element (4) and an outer cylindrical surface (7) coaxial to the first longitudinal axis (X) and configured to be coupled to a bearing (15) along a first portion of the first longitudinal axis (X), the coupling (1) further comprising coupling means (8) belonging to the second end (4b) to transmit the torque between the first coupling element (4) and the driving shaft (2), the coupling means (8) comprising recesses (9, 10) defined on the outer cylindrical surface (7) and developing according to the first longitudinal axis (X) from the end surface (4c) towards the first end (4a) for at least one part of the first portion of the first longitudinal axis (X).