Offset-Shaft Torque Coupling With Rolling Transfer Elements
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Solution Overview
Problem
Existing power transmission couplings between parallel offset axes often require large and complex components to maintain rotational speed and direction, especially when the distance between shafts is small, leading to inefficiencies and high frictional losses due to sliding contact.
Innovation Solution
A torque coupling system comprising a centre member and side members with congruent holes, utilizing torque transfer elements like cylindrical, elliptical, or spherical rollers that rotate about a third axis parallel to both main and secondary axes, enabling smooth rolling contact to transfer torque without speed or direction change.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional gears, chains, sprockets and belts are used to transfer power between parallel offset axes, then power transfer is achieved, but the components become large and complex when no speed difference is required
Solution Approach 1:
The coupling is divided into three separate members (centre member, left side member, right side member) that can be manufactured independently and assembled together. Each member contains holes that accommodate torque transfer elements, allowing the system to achieve complex power transfer functionality through simple, modular components rather than a single large complex mechanism
Solution Approach 2:
Torque transfer elements (rollers, pins, or projectiles) act as intermediaries between the centre member and side members. These elements roll between the holes of adjacent members, mediating the torque transfer from the input shaft to the output shaft while maintaining 1:1 speed ratio, thereby eliminating the need for complex traditional power transfer mechanisms
2Loss of energy
If traditional sliding contact mechanisms are used to transfer torque between parallel offset axes, then torque transfer is achieved, but frictional losses increase
Solution Approach 1:
The torque transfer elements utilize curved rolling surfaces (cylindrical rollers, spherical rollers, or elliptical rollers) instead of flat sliding surfaces. The rolling contact between the curved surfaces of the rollers and the holes in the members significantly reduces frictional losses and contact stress compared to traditional sliding contact mechanisms
Solution Approach 2:
The patent replaces the sliding friction-based mechanical contact with a rolling friction-based system. By substituting sliding contact with rolling contact through the use of rollers, the system achieves torque transfer with minimal energy loss and reduced wear, eliminating the harmful effects associated with high-friction sliding interfaces
3Speed
If large components are used to maintain rotational speed and direction between parallel offset axes, then speed consistency is maintained, but the coupling size increases
Solution Approach 1:
The patent introduces a third dimension by having torque transfer elements rotate about a third axis that is parallel to and disposed midway between the main axis and the secondary axis. This dimensional approach allows the elements to bridge the offset between parallel shafts effectively, maintaining speed consistency without requiring large coupling volumes
Solution Approach 2:
The torque transfer elements are nested within the holes of the centre and side members, with each roller contained within aligned holes that pass through the coupling members. This nested arrangement allows the torque transfer mechanism to be compact and integrated within the coupling structure, achieving speed consistency without increasing overall coupling size
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively transfers torque between parallel offset axes with minimal contact stress and friction, maintaining rotational speed and direction, while being compact and efficient, potentially replacing secondary gear sets in tight packaging scenarios.
Implementation Method 1
transfer torque between the centre member and the side members through rolling contact between the torque transfer elements and the holes of the centre and side members
Data Source
AI summary
A coupling includes left and right side members, and a centre member that is disposed between the side members. The centre member has a main axis of rotation, and includes holes disposed about the main axis at a radius. The side members each have a common offset axis of rotation parallel to and offset from the main axis. Each side member includes holes congruent with the holes in the centre member and disposed about the offset axis at the radius. Torque transfer elements extend through the holes of the centre member and into the holes of the side members. The torque transfer elements rotate about a third axis parallel to and disposed midway between the main axis and the offset axis, and transfer torque between the centre member and the side members through rolling contact between the torque transfer elements and the holes of the centre and side members.