Roller Bearing Shaft Coupling for Low-Backlash Misalignment

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Solution Overview

Problem

Existing flexible couplings for torque transmission between rotating shafts face challenges in manufacturing complexity, high frictional losses, and backlash, which increase costs and reduce efficiency.

Innovation Solution

A coupling assembly featuring a radially extending flange on one shaft and a hollow receiving member on the other, both with longitudinally extending grooves that accommodate a barrel-shaped roller bearing, enhancing torque transfer and reducing manufacturing complexity by using commercially available high-hardness roller bearings with smooth surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If boat-shaped spline teeth are used to accommodate angular misalignment, then clearance for misalignment is provided, but manufacturing difficulty increases

Engineering Contradiction:

Improveangular misalignment accommodationVSAvoidtooth shape manufacturing

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies curvature by using barrel-shaped rollers instead of boat-shaped teeth. The cylindrical/curved geometry of the rollers is simpler to manufacture than the complex boat-shaped splines, while still providing the necessary clearance and accommodation for angular misalignment through their rounded geometry and rocking motion capability.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent replaces the mechanical spline tooth engagement system with a roller-based torque transmission system. Instead of using complex interlocking boat-shaped teeth, the invention uses simpler cylindrical rollers that transmit torque through contact and rocking motion, significantly simplifying manufacturing while maintaining misalignment accommodation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If traditional flexible coupling components are used, then torque transmission is achieved, but frictional losses increase

Engineering Contradiction:

Improvetorque transmissionVSAvoidfrictional losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent replaces traditional flexible coupling components with a roller bearing-based system. The rollers transmit torque through rolling contact and rocking motion rather than sliding friction, significantly reducing frictional losses while maintaining effective torque transmission between misaligned shafts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the friction parameter by using rolling contact instead of sliding contact. The barrel-shaped rollers reduce frictional losses by transforming the friction mechanism from sliding to rolling, thereby improving energy efficiency while maintaining torque transmission capability.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If conventional coupling designs are used, then shaft connection is achieved, but backlash between shafts increases

Engineering Contradiction:

Improveshaft connectionVSAvoidbacklash reduction

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent uses the curved geometry of barrel-shaped rollers to minimize backlash. The rounded surfaces of the rollers maintain continuous contact with the grooves in the flange and receiving member, eliminating gaps and backlash that would occur with flat or angular contact surfaces in conventional couplings.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent replaces conventional coupling designs with a roller-based system that eliminates backlash through continuous rolling contact. The rollers maintain constant engagement with the grooves, preventing the play and gaps that characterize traditional flexible couplings.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution improves torque transfer efficiency, reduces frictional losses, and minimizes backlash, thereby simplifying manufacturing and reducing costs while accommodating axial misalignment.

Implementation Method 1

a barrel-shaped roller bearing provided to extend longitudinally within and in contact with both said flange groove and said receiving member groove

Methodology Applied

Scientific EffectRolling contact: Roller

Implementation Method 2

reduces frictional losses

Methodology Applied

Scientific EffectFriction reduction: Friction

Data Source

PatentUS10941814B2Coupling assembly

Publication Date: 2021.03.09 HAMILTON SUNDSTRAND CORP

AI summary

A coupling assembly for rotatably coupling two shafts comprises a first shaft extending longitudinally between a first end and a second end and having a radially extending flange at said second end; a second shaft extending longitudinally between a first end and a second end and having a radially extending hollow receiving member at said first end, the flange being positioned within the hollow receiving member, The hollow receiving member comprises an inner cylindrical surface comprising at least one longitudinally extending member groove and the flange comprises an outer cylindrical surface comprising at least one longitudinally extending flange groove, The coupling assembly also includes a barrel-shaped roller bearing provided to extend longitudinally within and in contact with both said flange groove and said receiving member groove and the flange groove and/or said member groove has a longitudinal concave barrel shape for receiving and contacting said barrel shaped roller bearing.