Shaft Flange Connection with Reduced Diameter for Bearing Replacement
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Solution Overview
Problem
The existing flange connections in roller presses are cumbersome to replace due to their large diameter, which prevents easy removal of machine elements like roller bearings, requiring complex and time-consuming disassembly and reassembly processes.
Innovation Solution
A shaft with varying diameters, where the flange diameter is smaller than the roller bearing seat, allowing the flange to be attached at a narrower point, enabling easy removal of roller bearings along the shaft without needing to remove the flange, and utilizing friction disks for stability and forged connections for mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the flange is designed with large flange blades to increase friction surface and stability, then the flange gains stability under torque load, but the diameter of the flange becomes significantly larger than the shaft diameter, making it difficult to remove machine elements along the shaft
Solution Approach 1:
The shaft is divided into sections with different diameters: a larger diameter section for the roller bearing seat and a smaller diameter section for the flange connection. This segmentation allows the flange to have sufficient friction surface for stability while maintaining a compact overall diameter that enables easy removal of machine elements along the shaft.
Solution Approach 2:
Different sections of the shaft are given different local qualities (diameters) to fulfill different functions. The larger diameter section provides adequate friction surface for the flange connection to handle torque, while the smaller diameter section allows machine elements to pass through easily during replacement operations.
2Adaptability or versatility
If a shrink disk is used to detachably connect the flange to the shaft, then the flange can be separated from the shaft, but the shrink disk must be dismantled and reassembled every time to replace rollers, considerably increasing replacement time
Solution Approach 1:
The shaft is pre-designed with a diameter variation that inherently allows easy removal of machine elements. The smaller diameter section is built into the shaft structure itself, eliminating the need for additional detachable connection mechanisms like shrink disks, thereby reducing replacement time while maintaining adaptability.
3Strength
If the flange diameter is made larger to ensure sufficient friction surface, then the torque transmission is improved, but the machine elements arranged on the shaft cannot be easily removed along the shaft
Solution Approach 1:
The shaft is segmented into different diameter sections, allowing the flange connection area to have adequate friction surface for torque transmission while the overall flange diameter remains compact due to the smaller diameter section, enabling easy removal of machine elements.
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
Facilitates quick and easy replacement of roller bearings by eliminating the need for expensive shrink disks and reducing the force required for movement, while maintaining mechanical stability through forged connections and friction disks.
Implementation Method 1
provision is made for one or more friction disks with a high coefficient of friction to be inserted between the flange. The friction disks increase the static friction between the flange and thus make the flange connection more stable.
Implementation Method 2
a shaft is a rod-shaped machine element that is used to transmit rotary movements and torques
Data Source
Figure 1
AI summary
The invention relates to a flange connection on a shaft (1) having at least two diameters (d1, d2) of different size, wherein the diameter (d3) of the flange connection is smaller than the diameter (d1) of the rolling bearing seat (2). Machine parts on the shaft can thereby be rapidly and simply interchanged without the flange (3) having to be removed in the process.