Safety Coupling Torque Sensor Integration for Compact Overload Control
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Solution Overview
Problem
Existing safety couplings face challenges in maintaining compactness while effectively measuring and managing torque, often requiring additional space for torque sensors and complex energy transmission systems.
Innovation Solution
A compact safety coupling design with a torque sensor element integrated within a recess of one coupling member, utilizing a non-rotating transmitter/receiver and guidance elements to maintain compactness, and employing strain gauges for reliable torque measurement, along with a pressure element for frictional engagement and wireless energy transfer to minimize construction space and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a torque sensor is integrated into the safety coupling, then torque measurement capability is improved, but the device complexity increases
Solution Approach 1:
The torque sensor element is integrated directly into the coupling member structure, merging the sensing function with the mechanical coupling component. This eliminates the need for separate sensor housings and mounting mechanisms, thereby improving torque measurement capability while minimizing the increase in device complexity
Solution Approach 2:
The coupling member serves multiple functions: it transmits torque mechanically and simultaneously houses the torque sensor element for measurement. This multi-functionality approach allows the same component to fulfill both structural and sensing roles, resolving the contradiction between added measurement capability and device complexity
2Use of energy by moving object
If a rotating transmitter/receiver is arranged on the outer surface for wireless energy transfer, then energy transmission is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent replaces traditional wired mechanical connections for energy transmission with a wireless energy transfer system using electromagnetic fields. The rotating transmitter/receiver arrangement on the outer surface enables contactless power and data transmission, improving energy transfer efficiency while the compact outer surface mounting minimizes the added complexity
3Reliability
If the torque sensor element is arranged within a recess of the coupling member, then the sensor is protected from damage, but the manufacturing precision requirements increase
Solution Approach 1:
The torque sensor element is nested within a recess of the coupling member, similar to a doll within a doll structure. This nesting arrangement provides inherent mechanical protection to the sensor element while the recess is designed with tolerances that balance protection needs with manufacturing feasibility. The sensor is housed within the existing coupling member geometry rather than requiring separate protective structures
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 allows for precise torque measurement and control, preventing over-torque situations while maintaining a compact form factor and reducing production costs, with enhanced reliability and ease of sensor replacement.
Implementation Method 1
The transferred torque is measured by a torque sensor. The torque sensor comprises a torque sensor element.
Implementation Method 2
A friction connection is provided by surface pressure. Therefore the twin wallet hollow sleeve is expanded by pressurized hydraulic oil.
Data Source
Figure 1~2
Figure 3
AI summary
Safety coupling (1) comprising a driving coupling member (11), a driven coupling member (20), a torque sensor (2) and an engagement mechanism to provide a connection of the coupling members (11, 20). The transferrable torque is adjustable to a predefined torque value by the engagement mechanism. The transferred torque is measured by a torque sensor (2) comprising a torque sensor element (3), wherein the torque sensor element (3) is arranged within a recess of one coupling member (11, 20), preferable the driven coupling member (20).