Shear-Pin Mechanical Connector for High Torque Transfer
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Solution Overview
Problem
Existing mechanical connectors, such as the Merlin™ family connectors, face limitations in handling high torsional loads and require improvements in design to enhance their torsional load capacities and fatigue strength, particularly in offshore engineering applications where high torsional and bending loads are prevalent.
Innovation Solution
The introduction of structural features like dog-clutch teeth, fitted pins, keys, splines, and interlocked thread systems, combined with modifications in the shapes of boxes and pins, and the use of assembly/disassembly fluids that solidify at operational temperatures, to enhance the connectors' ability to transfer high torsional loads and improve stiffness and weight control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional Merlin family connectors are used, then axial and bending load capacities are high, but torsional load capacities are limited and difficult to control accurately
Solution Approach 1:
The connector is divided into distinct functional segments: a box component, a pin component, and separate torque transfer elements (such as dog-clutch teeth, fitted pins, keys, or splines). This segmentation allows the torque transfer mechanism to be independently optimized without redesigning the entire connector, thereby increasing torsional load capacity while managing structural complexity.
Solution Approach 2:
Intermediary torque transfer elements are introduced between the box and pin components. These intermediaries (dog-clutch teeth, fitted pins, keys, splines, or interlocked thread systems) serve as mediators that specifically address torque transfer, allowing the main connector body to remain relatively simple while the intermediary elements provide enhanced torsional load capacity.
2Strength
If variable outside stress diameters and inside stress diameters are implemented, then torsional load capacity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The connector components feature locally varied properties: the outside stress diameter and inside stress diameter are optimized at different locations along the box and pin. For example, the box may have a larger outside diameter at the torque transfer region compared to the end regions, while the pin may have corresponding variations in inside diameter. This local quality optimization enhances torsional load capacity at critical regions without requiring uniform complexity throughout the entire component.
3Reliability
If assembly/disassembly fluids that solidify at operational temperatures are used, then leak resistance and stiffness are improved, but ease of operation during assembly decreases
Solution Approach 1:
The connector utilizes assembly/disassembly fluids that undergo phase transitions between liquid and solid states. During assembly, the fluid is in liquid form, allowing easy injection and distribution within the connector components. Once assembly is complete and operational temperature is reached, the fluid solidifies, providing enhanced leak resistance and stiffness. This phase transition mechanism allows the fluid to serve dual purposes: facilitating easy assembly in liquid state and providing structural integrity in solid state.
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 novel connectors achieve high torsional and bending load capacities while maintaining high axial load capacities, allowing for efficient use in smaller sizes and lower design pressures, with improved weight control and leak resistance, making them suitable for demanding offshore applications.
Implementation Method 1
the use of assembly/disassembly fluids that solidify at operational temperatures
Implementation Method 2
frictional resistance resulting from radial and axial connector preload
Implementation Method 3
structural features like dog-clutch teeth, fitted pins, keys, splines, and interlocked thread systems
Data Source
AI summary
This invention builds up on technical features and on the industry experience with the use of Merlin™ family connectors. In addition to friction, structural means utilized to transfer high torsional loads include shear pins and may also include: interlocked thread systems, dog-clutch teeth, keys and splines, all used in isolation or in arbitrary combinations. Static and fatigue bending load capacities of the connectors remain high, while the axial load capacities may or may not be high, depending on the design requirements. Connectors according to this invention can be built as new, carefully optimized designs. In some cases upgrading existing Merlin™ family connector designs to increase they torque transfer capacities may be also feasible.