Reversible Driveline Coupler Saddle for Multi-Shape Shaft Fit

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Solution Overview

Problem

Existing driveline couplers lack the ability to easily adapt to different sizes and shapes of drive shafts, such as square and round shafts, and do not incorporate a reversible saddle design, limiting their versatility and compatibility with various shaft configurations.

Innovation Solution

A driveline coupler with a reversible saddle that can be easily switched between configurations to accommodate different sizes and shapes of drive shafts, including square, round, and triangular shafts, by simply reversing the saddle, allowing for a wider range of sizes and configurations without the need for shims, and enabling easy interchangeability with other brands and types of couplers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a traditional fixed-configuraton driveline coupler is used, then the structure is simple and manufacturing is easy, but it cannot adapt to different sizes and shapes of drive shafts

Engineering Contradiction:

Improveadaptability to different shaft sizes and shapesVSAvoidcoupler structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The saddle is designed with a reversible configuration that allows it to dynamically change its engagement surface orientation. By rotating the saddle 180 degrees, the coupler can adapt between different shaft configurations (square vs. round, different sizes) without requiring multiple separate coupler bodies, thus achieving versatility while maintaining relatively simple structure

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The driveline coupler incorporates a universal saddle design with multiple engagement surfaces on a single component. One surface is configured for square shafts while the opposite surface is configured for round shafts, allowing the same coupler body to universally accommodate different shaft types and sizes through simple reorientation

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If multiple separate couplers are used for different shaft configurations, then each coupler can be optimized for its specific function, but the overall system complexity increases and field modifications become difficult

Engineering Contradiction:

Improveease of field modificationVSAvoidnumber of different coupler types

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Instead of using multiple specialized couplers for different shaft types, the invention inverts the approach by putting multiple engagement configurations into a single reversible saddle. The operator can easily switch between configurations by simply rotating the saddle 180 degrees in the field, eliminating the need to carry or install multiple different coupler types

Inventive Principle:

Principle #13The other way round (Inversion)

3Adaptability or versatility

If a reversible saddle design is implemented, then versatility with different shaft configurations is achieved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecompatibility with various shaft configurationsVSAvoidsaddle configuration precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The reversible saddle incorporates different local engagement surface geometries optimized for specific shaft types. One side features surfaces configured for square shaft engagement while the opposite side has surfaces for round shaft engagement. Each local surface is precisely manufactured for its specific function, allowing high versatility without requiring the entire saddle to meet all precision requirements simultaneously

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12178166B2Dynamic reversible multi-cross section universal modular driveline coupler

Publication Date: 2024.12.31 VALMONT INDUSTRIES INC

AI summary

Apparatus and method for an improved driveline coupler having a reversible saddle thereon which allows it to be configured to work with different sizes and shapes of shafts. The reversible saddle is configured on one side to work with one size of driveline shaft and configured on the opposite side to work with a different size driveline shaft so that, in the field, an operator can modify the driveline coupler from use with a first size of drive shaft to a second size of drive shaft easily and quickly by turning the saddle upside down.