Spline Alignment Tool Using Expandable Elastomer Plugs
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Solution Overview
Problem
Conventional alignment solutions fail to accurately align rotating machinery components with female internally splined shafts, such as motor-driven propellers, leading to issues like excessive vibrations, lubricant leakage, premature wear, and coupling failures.
Innovation Solution
The use of expandable elastomer plugs inserted into the motor and gearbox, secured by axial compression, to align internally splined shafts, ensuring proper alignment without damaging the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment solutions are used for female internally splined shafts, then alignment can be performed, but the shafts are damaged and alignment accuracy is poor
Solution Approach 1:
The patent introduces an intermediary alignment tool with external splines that mate with the internal splines of the female shafts. This intermediary tool provides a protective interface during alignment, preventing direct contact and damage between alignment equipment and the delicate internal splines. The tool's external splines engage with the internal splines without causing damage, enabling accurate alignment while preserving the shaft integrity.
Solution Approach 2:
The alignment tool is designed as a disposable or single-use component that is inserted into the female shafts for alignment purposes and then removed. This approach allows the use of a simpler, less expensive tool rather than risking damage to the expensive shafts. The tool can be discarded or reused a limited number of times, making it economically viable to use for each alignment operation without concern for tool wear or damage to the shafts.
2Productivity
If conventional alignment tools are used, then alignment process can be completed, but excessive vibrations and premature wear occur due to misalignment
Solution Approach 1:
The patent replaces conventional mechanical alignment methods with a specialized alignment tool system designed specifically for female internally splined shafts. This new mechanical system provides more accurate alignment capability, ensuring proper shaft alignment that prevents excessive vibrations and premature wear. The tool's design allows for precise positioning and alignment that conventional methods cannot achieve with internal splines.
3Reliability
If proper alignment is achieved, then machinery reliability improves, but the alignment process becomes more complex
Solution Approach 1:
The alignment tool is segmented into distinct functional components: a body portion that engages with the internal splines, external splines for mating with alignment equipment, and a protective design that separates the alignment function from the shaft. This segmentation allows each component to perform its specific function effectively while maintaining overall simplicity. The modular design makes the tool easier to manufacture and use despite the specialized requirements for aligning female internally splined shafts.
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
This method effectively aligns motor-driven propellers, reducing stress on machinery, improving part lifespan, and enhancing safety by minimizing damage to internal splines.
Implementation Method 1
The use of expandable elastomer plugs inserted into the motor and gearbox, secured by axial compression
Implementation Method 2
secured by axial compression
Data Source
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AI summary
Methods, apparatus, systems, and articles of manufacture are disclosed. An example apparatus includes a tubular body (205, 227) including a shaft (212, 232), a shoulder (208, 228), and a neck (207, 235), the shaft (212, 232) coupled to the shoulder (208, 228), the shoulder (208, 228) coupled to the neck (207, 235), the shoulder (208, 228) having a greater diameter than respective diameters of the shaft (212, 232) and the neck (207, 235); a plug (204, 224) coupled to the neck (207, 235) at a first plug edge (304) and coupled to a first fastener (220, 242) at a second plug edge (310), the first fastener (220, 242) including a hole (216, 240); and a second fastener (218, 238) coupled to the first fastener (220, 242), the second fastener (218, 238) extending through the tubular body (205, 227), the plug (204, 224), and the first fastener (220, 242).