Segmented Torque Coupling for Misalignment and Assembly Control
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Solution Overview
Problem
Existing coupling designs for gas turbine engines face challenges in accommodating misalignment between rotary components while maintaining dynamic stress resistance, low friction, and minimizing weight, particularly in aeronautical applications where precise axis alignment is difficult to achieve.
Innovation Solution
A coupling system with circumferentially distributed segments that extend radially from one coupler to another, featuring offset connections and tabs that prevent incorrect orientation, allowing for deeper penetration in the correct orientation and limiting misalignment-induced stress through compressive deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the degree of tolerance to misalignment is increased, then ease of operation is improved, but dynamic stress resistance deteriorates
Solution Approach 1:
The coupling is divided into multiple segments circumferentially distributed about the axis, with each segment independently engaging between the first and second couplers. This segmentation allows each segment to accommodate misalignment locally while collectively maintaining torque transfer capability and dynamic stress resistance across the entire coupling assembly.
Solution Approach 2:
The segments are designed to rotate about the axis and can dynamically adjust their orientation to accommodate misalignment between the first and second couplers. The differential penetration depths in different orientations enable the segments to adapt to varying alignment conditions while maintaining engagement and torque transfer.
2Power
If the penetration depth of the segment is increased in the correct orientation, then torque transfer capability is improved, but the risk of incorrect assembly increases
Solution Approach 1:
The segment is designed with asymmetric features including a first tab protruding from one axial end face and a second tab from the opposite end face, with different radial heights. The first tab has height greater than the gap between the retaining ring and peripheral wall, while the second tab has height less than the gap. This asymmetry creates different penetration depths for opposite orientations, enabling deeper engagement in the correct orientation while preventing full insertion in incorrect orientation.
3Adaptability or versatility
If the number of segments is increased to accommodate misalignment, then adaptability is improved, but device complexity increases
Solution Approach 1:
Each segment is designed as a universal component that performs multiple functions: transferring torque, accommodating misalignment through rotation and orientation adjustment, and providing assembly guidance through asymmetric tabs. The segments are circumferentially distributed and radially offset, allowing the same segment design to be repeated around the axis, reducing overall system complexity while maintaining adaptability.
Data Source
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AI summary
A coupling (30) has: a first coupler (31) rotatable about an axis (A1) and defining first connections (35A) distributed about the axis (A1); a second coupler (33) defining second connections (37A) distributed about the axis (A1), the second connections (37A) offset from the first connections (35A); and segments (44) distributed about the axis (A1) and extending radially from the first connections (35A) to the second connections (37A), a segment (44) of the segments (44) having a first end (48) engaging a first connection (35A) of the first connections (35A) and a second end (46) engaging a second connection (37A) of the second connections (37A), the first end (48) circumferentially offset from the second end (46), a face (47A) of the segment (44) abutting against a face of the first coupler (31) when the segment (44) is inserted into the first connection (35A) in a first orientation such that a penetration depth of the segment (44) into the first connection (35A) in the first orientation is less than the penetration depth in a second orientation opposite the first orientation.