Optical Coupling Hub Monitoring for Shaft Locking Position
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in mechanical couplings is the difficulty in determining if shafts are properly positioned within hubs after assembly, leading to potential loose locking and axial displacement, which can result in reduced torque-carrying capacity and failure of engagement, affecting product repeatability and yield, especially in semiconductor fabrication processes.
Innovation Solution
The implementation of a coupling monitoring system with aligned through holes on each hub, allowing for automated position monitoring using a sensor system to detect light transmission, which indicates proper locking and potential axial displacement, triggering alarms or stopping operations when thresholds are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated monitoring using sensor systems is implemented, then shaft position monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical sensing system. Light sources and sensors are used to detect shaft position through the coupling hub, eliminating the need for mechanical dial indicators or other complex mechanical measurement devices. This substitution maintains high measurement precision while reducing mechanical complexity.
Solution Approach 2:
The patent introduces light as an intermediary to detect shaft position. Instead of direct mechanical contact or complex electronic sensors, light passes through the coupling hub and shaft assembly, and changes in light transmission indicate shaft displacement. This intermediary approach simplifies the monitoring system while maintaining measurement capability.
2Reliability
If shaft position monitoring is implemented, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The monitoring system is segmented into separate functional components: light sources, light detectors, signal processing circuits, and alarm systems. This segmentation allows each component to be manufactured and tested independently, then assembled into the complete monitoring system. The through-holes in the coupling hub are also segmented features that can be manufactured using standard drilling and machining processes.
Solution Approach 2:
The coupling hub serves multiple functions: it mechanically connects the shafts and simultaneously acts as a housing for the optical monitoring components. The through-holes serve dual purposes of mechanical structural features and optical pathways for detection. This multi-functionality reduces the need for separate monitoring device manufacturing.
3Measurement precision
If light transmission monitoring is used, then detection precision is improved, but energy consumption increases
Solution Approach 1:
The light sources in the monitoring system can be operated periodically rather than continuously. The system can sample shaft position at predetermined time intervals or based on operational conditions, reducing energy consumption while maintaining sufficient detection precision for reliability monitoring.
Solution Approach 2:
The system can adjust light source intensity and detection sensitivity based on operational conditions. During normal operation, lower intensity light and reduced detection frequency can be used. When abnormal conditions are detected or during critical operations, the system increases light intensity and detection frequency, optimizing the balance between detection precision and energy consumption.
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
This solution ensures proper locking and prolonged operation by monitoring shaft positions within hubs, preventing axial displacement and maintaining stability, repeatability, and yield in semiconductor device fabrication processes.
Implementation Method 1
an optical emitter configured to emit light through the through hole to the optical sensor
Implementation Method 2
an optical sensor configured to detect light transmitted through the through hole
Data Source
AI summary
A coupling including a main body, a first hub at a first end of the main body and a second hub at a second end of the main body opposite the first end is provided. The first hub includes a first inner bore configured to receive a first shaft and a pair of aligned first and second through holes extending through opposite walls of the first hub. The first through hole and the second through hole are in optical communication with the first inner bore.