Shaft Spline Coupler With Integrated Lubrication Flow Path
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Solution Overview
Problem
Conventional coupling devices in vehicles fail to adequately transfer torque due to short durability and lack of lubrication, leading to axial forces and heat-induced damage, which reduces torque transfer and affects overall vehicle performance.
Innovation Solution
A coupling device with a housing featuring sets of splines of equal length for engaging input and output shafts, a shoulder with thrust surfaces to withstand axial loads, and a flow path for lubrication that ensures consistent lubrication of splines, canceling out axial forces and extending component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coupling devices are used to transfer torque, then torque transfer is achieved, but durability is short and components fail quickly
Solution Approach 1:
A flow path is introduced as an intermediary structure within the coupling device to deliver lubrication from the lubrication source to the splines and thrust surfaces. This mediator enables sustained lubrication without requiring external intervention, thereby extending component life and improving reliability
Solution Approach 2:
The coupling device is pre-equipped with integrated lubrication delivery features (flow paths, openings, and thrust surfaces with lubrication holes) that ensure lubrication is available before components fail. This preliminary preparation prevents premature failure by ensuring continuous lubrication throughout the component's operational life
2Reliability
If adequate lubrication is not provided to components, then device complexity is reduced, but components overheat and fatigue quickly
Solution Approach 1:
The lubrication delivery function is merged with the structural components of the coupling device. The thrust surfaces and spline interfaces are integrated with lubrication holes and flow paths, combining structural support and lubrication delivery into single elements. This reduces overall device complexity while ensuring adequate lubrication
Solution Approach 2:
The coupling device is designed to self-lubricate through integrated flow paths that automatically deliver lubrication from the lubrication source to critical surfaces. The device serves its own lubrication needs without requiring external lubrication systems or manual intervention, maintaining simplicity while ensuring component durability
3Reliability
If thrust surfaces are not provided to withstand axial loads, then device complexity is reduced, but axial forces cause damage and reduce torque transfer
Solution Approach 1:
The thrust surfaces serve multiple functions: they withstand axial loads from torsional vibrations, provide lubrication delivery points through integrated holes, and maintain structural integrity during operation. This multi-functionality reduces the need for separate components, maintaining simplicity while ensuring reliable torque transfer
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 coupling device effectively transfers torque by balancing axial forces and providing sustained lubrication, reducing wear and damage, thereby enhancing vehicle performance and extending the lifespan of components.
Implementation Method 1
the coupler comprises a flow path configured to direct lube from a lube source to the splines and the thrust surfaces
Data Source
AI summary
The present invention provides a coupling device for coupling an input shaft to an output shaft. The coupling device includes a housing having a first end and a second end. The coupling device further includes a first and second set of splines defined along the inner wall of the housing. The first set of splines is disposed near the first end and is configured for engaging splines of the input shaft. The second set of splines is disposed near the second end of the housing and is configured for engaging splines of the output shaft. The length of the first set of splines is substantially the same as the length of the second set of splines.