Shaft Coupling Assembly With Barrel Rollers for Misalignment and Low Backlash
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Solution Overview
Problem
Existing flexible couplings for torque transmission between rotating shafts face challenges in manufacturing complexity, frictional losses, and backlash, which increase costs and reduce efficiency in accommodating axial misalignment.
Innovation Solution
A coupling assembly featuring barrel-shaped roller bearings with curved grooves in both the flange and hollow cylindrical member, allowing for improved torque transfer and reduced pressure points, manufactured with high hardness and smooth surfaces to minimize edge chipping and enhance alignment flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If boat-shaped spline teeth are used to accommodate angular misalignment, then clearance for misalignment is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent applies curvature by using barrel-shaped rollers instead of rigid boat-shaped teeth. The cylindrical geometry of the rollers naturally accommodates angular misalignment through their ability to rock and pivot, eliminating the need for complex boat-shaped profiles while maintaining misalignment accommodation capability.
Solution Approach 2:
The invention replaces the mechanical interlocking of boat-shaped spline teeth with a roller-based system where torque is transmitted through friction and contact between the rollers, flange, and hollow cylindrical member. This substitution simplifies manufacturing while achieving the same functional goal of accommodating misalignment.
2Device complexity
If traditional rigid couplings are used for torque transmission, then structural simplicity is maintained, but frictional losses and backlash increase
Solution Approach 1:
The patent introduces dynamic elements by using rollers that can pivot and adjust their orientation based on the misalignment conditions. This dynamic adaptation allows the coupling to maintain optimal contact and minimize frictional losses while accommodating misalignment, unlike static rigid couplings.
Solution Approach 2:
The invention changes the physical parameters of the coupling system by introducing rolling contact instead of sliding contact between components. This parameter change from sliding to rolling significantly reduces frictional losses while maintaining structural simplicity through the use of standard roller bearing geometries.
3Manufacturing precision
If high precision manufacturing is applied to reduce backlash, then alignment precision is improved, but manufacturing costs increase
Solution Approach 1:
The barrel-shaped rollers with their curved geometry inherently compensate for minor misalignments and backlash through their ability to pivot and adjust. This geometric feature reduces the need for high-precision manufacturing while maintaining good alignment, as the curved surfaces naturally accommodate small variations in positioning.
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 enhances torque transfer efficiency, reduces manufacturing complexity and costs, and minimizes backlash, effectively accommodating axial misalignment while preventing edge chipping and improving the overall performance of torque transmission systems.
Implementation Method 1
A coupling assembly featuring barrel-shaped roller bearings with curved grooves in both the flange and hollow cylindrical member, allowing for improved torque transfer and reduced pressure points
Implementation Method 2
manufactured with high hardness and smooth surfaces to minimize edge chipping and enhance alignment flexibility
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3A~3B
AI summary
A coupling assembly for rotatably coupling two shafts is described. A method for rotatably coupling two shafts is also described. The coupling assembly comprises a first shaft (20) extending longitudinally between a first end and a second end and having a radially extending flange (30) at said second end; a second shaft (50) 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 (54); and wherein said hollow receiving member comprises an inner cylindrical surface (544) comprising at least one longitudinally extending member groove (56); and wherein said flange comprises an outer cylindrical surface comprising at least one longitudinally extending flange groove (32); said coupling assembly further comprising a barrel-shaped roller bearing (40) provided to extend longitudinally within and in contact with both said flange groove and said receiving member groove and further wherein said flange groove and/or said member groove has a longitudinal concave barrel shape for receiving and contacting said barrel shaped roller bearing.