Drive Element Clamp for Optical Systems
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Solution Overview
Problem
Existing attachment mechanisms for drive elements in optical instruments, such as welding, gluing, and collets, are inadequate for providing a robust and serviceable connection to shafts, often resulting in brittle joints, limited torque capacity, and difficulty in maintaining friction in dirty environments, while larger mechanisms like tapered collars and splines are costly and inconvenient for servicing.
Innovation Solution
A clamp-based attachment system with a base and retainer that compressively secures the drive element to the shaft, utilizing a cylindrical surface engagement and a fastener in a transverse hole for robust and removable attachment, allowing for easy installation and servicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to attach the drive element to the shaft, then the joint strength is improved, but the joint becomes brittle and causes softening of the metal
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical attachment system consisting of a set screw engaging a transverse hole and a flat surface region. This mechanical substitution eliminates the brittle joint characteristics and metal softening caused by welding, while providing sufficient attachment strength for the drive element.
2Ease of manufacture
If gluing is used to attach the drive element to the shaft, then the attachment is simple, but the shear strength is limited to below 400 psi
Solution Approach 1:
The patent divides the attachment function into two distinct components: a set screw that provides axial clamping force and a flat surface region that provides torque transmission. This segmentation allows the attachment to achieve both simplicity of assembly and high shear strength, overcoming the limitations of gluing which provides only limited shear strength.
3Volume of moving object
If a collet is used to attach the drive element to the shaft, then the attachment is compact, but the friction coefficient must be above a certain value which is difficult to achieve in dirty environments
Solution Approach 1:
The patent introduces a flat surface region as an intermediary between the drive element and shaft. This flat surface provides a dedicated torque transmission interface that does not rely on friction between the collet and shaft, thereby eliminating the friction coefficient requirement and making the attachment reliable in dirty environments while maintaining compact dimensions.
4Ease of repair
If a single set screw is used to make the drive element removable, then the serviceability is improved, but the set screw only makes contact at one point and tends to loosen with reverse cycling
Solution Approach 1:
The patent enhances the local quality of the shaft by providing a flat surface region specifically designed for torque transmission. This localized feature works in conjunction with the set screw to distribute contact forces, preventing the set screw from loosening during reverse cycling while maintaining easy serviceability. The flat surface creates a stable interface that prevents rotational movement of the set screw.
5Strength
If larger attachment mechanisms like tapered collars and splines are used, then the attachment strength is improved, but the size and cost increase
Solution Approach 1:
The patent merges the attachment function into a compact integrated system where the set screw and flat surface region work together as a unified mechanism. This merged design provides attachment strength comparable to larger mechanisms like tapered collars and splines, but in a much more compact form factor that is suitable for optical instruments with space constraints.
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 clamp-based attachment system provides a compact, robust, and easily removable connection that withstands operational loads, maintains serviceability, and is suitable for various gear ratios, addressing the limitations of existing methods.
Implementation Method 1
a clamp having a base and a retainer that compressively secure the drive element to the shaft
Implementation Method 2
a fastener disposed in threaded engagement with a transverse hole defined by the shaft
Implementation Method 3
engagement of a cylindrical surface region of the shaft with the base and engagement of a flat surface region of the shaft with the retainer
Data Source
AI summary
Optical system comprising a motor, an optical element, an optical detector, and a linkage that connects operation of the motor to movement of the optical element and the optical detector relative to one another. The linkage may include a shaft and a drive element that operatively connects the shaft to another part of the linkage. In some embodiments, the drive element may include a clamp having a base and a retainer that compressively secure the drive element to the shaft by engagement of a cylindrical surface region of the shaft with the base and engagement of a flat surface region of the shaft with the retainer. In some embodiments, the drive element may include a collar secured to the shaft with a fastener disposed in threaded engagement with a transverse hole defined by the shaft.