Spline Alignment Tool With Expandable Plug Locking
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Solution Overview
Problem
Conventional alignment solutions fail to accurately align driver and driven components with female internally splined shafts, such as in high-speed rotating machinery, leading to issues like excessive vibrations, premature wear, and coupling failures.
Innovation Solution
The use of expandable elastomer plugs inserted into the gearbox and motor, which expand due to axial compression, securing alignment tools in place and allowing for precise alignment of motor-driven propeller systems with female splined shafts, enabling accurate centerline alignment without protruding features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional alignment solutions are used for female internally splined shafts, then alignment can be performed, but alignment accuracy deteriorates leading to excessive vibrations and premature wear
Solution Approach 1:
The patent introduces alignment tools with expandable elastomer plugs as intermediary devices that insert into the female internally splined shafts. These plugs expand axially under compression to radially engage the internal splines, providing a reliable intermediary connection between the alignment tools and the shafts, thereby enabling accurate alignment without directly modifying the shafts themselves
Solution Approach 2:
The elastomer plugs undergo parameter changes through axial compression that transforms into radial expansion. By applying axial force to compress the plugs, they expand radially to engage the internal splines of the female shafts, providing secure attachment for the alignment tools. This parameter transformation enables reliable engagement without damaging the shafts
2Ease of operation
If alignment tools are inserted into female splined shafts without expandable plugs, then insertion is easy, but the tools cannot be securely locked in place
Solution Approach 1:
The alignment tools incorporate dynamically expandable elastomer plugs that transition from a compressed state during insertion to an expanded state during alignment. The plugs are inserted in a compressed condition allowing easy insertion, then expanded axially under compression to radially engage the internal splines, securing the tools in place while maintaining alignment precision
3Strength
If rigid plugs are used to secure alignment tools, then secure locking is achieved, but damage to internal splines occurs
Solution Approach 1:
The elastomer plugs undergo parameter changes through axial compression that transforms into radial expansion. By applying axial force to compress the plugs, they expand radially to engage the internal splines, providing secure attachment for the alignment tools. This parameter transformation enables reliable engagement without damaging the shafts
Solution Approach 2:
The patent uses elastomer material with specific properties that combine flexibility and strength. The elastomer plugs have enough compliance to engage the internal splines without causing damage, yet provide sufficient locking strength to securely hold the alignment tools in place during the alignment process
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 ensures proper alignment of high-speed rotating machinery, reducing stress, improving part lifespan, and enhancing safety by securely locking the alignment tools in place without damaging the internal splines, thus preventing misalignment-related failures.
Implementation Method 1
the plug expanding in response to the axial compression
Data Source
AI summary
Methods, apparatus, systems, and articles of manufacture are disclosed. An example apparatus includes a tubular or cylindrical body including a shaft, a shoulder, and a neck, the shaft coupled to the shoulder, the shoulder coupled to the neck, the shoulder having a greater diameter than respective diameters of the shaft and the neck. The example apparatus includes a plug coupled to the shoulder at a first plug edge and coupled to a first fastener at a second plug edge, the first fastener including a hole. The example apparatus includes a second fastener coupled to the first fastener, the second fastener extending through the tubular body, the plug, and the first fastener.