Self-Aligning Torque Coupler for Foundation Piling
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Solution Overview
Problem
Existing foundation support systems face challenges in aligning and connecting piling and extension pieces due to the difficulty in aligning fastener holes, leading to compromised system integrity and reliability, especially when subjected to torque during deep piling.
Innovation Solution
An interlocking, self-aligning, and torque-transmitting coupler assembly with primary and secondary alignment features, such as ribs and grooves, facilitates easy connection between piling and extension pieces, ensuring proper alignment and mechanical isolation of fasteners from torque, eliminating the need for aligned fastener holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing coupler systems with fastener holes are used to connect piling and extension pieces, then the connection can be made with simple structure, but the alignment of fastener holes becomes extremely difficult when extension pieces are long and heavy, compromising system integrity
Solution Approach 1:
The coupler body is pre-formed with recesses and the extension piece is pre-formed with protrusions that automatically align when the components are assembled. This preliminary configuration of alignment features eliminates the need for manual alignment of fastener holes during installation, resolving the contradiction between simple connection structure and precise alignment requirement
Solution Approach 2:
The coupler body acts as an intermediary component between the piling and extension piece. It incorporates alignment recesses that receive alignment protrusions from both the piling and extension piece, serving as a mediator that facilitates automatic alignment without requiring precise manual positioning of fastener holes
2Reliability
If piling is driven deeply into the ground to provide adequate support, then foundation stability is improved, but the weight and length of extension pieces increase making alignment and connection extremely difficult
Solution Approach 1:
The alignment protrusions and recesses are pre-configured on the components before installation. When the heavy extension piece needs to be connected to the deeply driven piling, the pre-formed alignment features automatically guide the connection, making the operation feasible despite the increased weight and length required for deep foundation support
Solution Approach 2:
The coupler assembly system is self-aligning through its geometric features (recesses and protrusions) that automatically position components correctly during assembly. This self-service alignment mechanism eliminates the need for external alignment tools or complex positioning procedures, making connection easier even when foundation stability requires deep piling with heavy extension pieces
3Device complexity
If fasteners are used to connect piling and extension pieces in existing systems, then the connection can be made with simple components, but the fastener holes deform when subjected to torque during deep piling, compromising system integrity
Solution Approach 1:
The invention extracts the alignment function from the fastener holes and relocates it to dedicated alignment protrusions and recesses. This separation of functions allows the fasteners to focus solely on providing torque-resistant connection without the additional stress of maintaining alignment, preventing hole deformation and preserving system integrity under torque while keeping the overall connection structure relatively simple
Solution Approach 2:
The coupler body serves as an intermediary that absorbs and distributes torque through its robust structure and geometric alignment features. The alignment recesses and protrusions transfer torque loads through the coupler body rather than directly through fastener holes, protecting the fastener holes from deformation while maintaining connection integrity
Data Source
AI summary
A self-aligning and torque transmitting coupler assembly includes an outer coupler coupled to a first shaft of and an inner coupler coupled to a second shaft. The outer coupler comprises an inner surface having primary and secondary alignment and torque transmitting features, and the inner coupler comprises an outer surface having primary and secondary alignment features. The primary and secondary alignment features are configured to interlock and facilitate alignment of the first and second shafts along a common axis in an exemplary application of a foundation support system.