Spring-Biased Spline Coupling for Supercharger Overload Disengagement
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Solution Overview
Problem
Existing drive shaft assemblies in superchargers face challenges in managing unequal loads between the driven and drive sections, particularly under conditions of high torque or foreign object interference, which can disrupt normal operation.
Innovation Solution
A drive shaft assembly with a first and second spline coupling and a spring, where the spring biases the couplings into engagement and converts rotational loads exceeding frictional forces into linear loads, allowing the couplings to disengage and rotate at different rates, reducing excessive load transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the spline coupling is designed to transmit high torque loads, then the power transmission capability is improved, but the risk of foreign object interference and excessive load damage increases
Solution Approach 1:
The drive shaft assembly is divided into multiple sections with two spline couplings (first and second spline couplings) that can slide relative to each other along the longitudinal axis. This segmentation allows the system to isolate and manage high torque loads in specific zones, preventing foreign objects from causing catastrophic damage to the entire drive shaft. The modular design enables the foreign object damage isolation mechanism to protect critical components while maintaining power transmission capability.
Solution Approach 2:
The spring acts as an intermediary element between the two spline couplings, providing a controlled compliance mechanism. When foreign objects or excessive loads are encountered, the spring allows the spline couplings to slide relative to each other, absorbing shock and preventing direct transmission of damaging forces. This intermediary mechanism maintains power transmission under normal conditions while protecting against damage during abnormal conditions.
2Power
If the spline coupling interface is designed with high frictional force, then the torque transmission efficiency is improved, but the ability to disengage under excessive load is reduced
Solution Approach 1:
The spline coupling interface transitions between two dynamic states: engaged and disengaged. During normal operation, the high frictional force maintains the engaged state for efficient torque transmission. When excessive loads or foreign objects are encountered, the spring force overcomes the frictional force, allowing the couplings to slide and disengage. This dynamic behavior enables the system to adapt to varying load conditions, maintaining efficiency when needed and providing protection when necessary.
Solution Approach 2:
The system changes the effective frictional force parameter at the spline coupling interface based on load conditions. Under normal operation, high friction maintains engagement. Under excessive load conditions, the spring force changes the balance of forces, reducing the effective frictional resistance and enabling disengagement. This parameter change allows the system to switch between torque transmission and load isolation modes.
3Reliability
If the spring force is increased to maintain engagement under high torque, then the reliability of power transmission is improved, but the ability to allow disengagement under foreign object interference is reduced
Solution Approach 1:
The spring provides beforehand cushioning by being pre-loaded to exert a biasing force that maintains engagement between the spline couplings during normal high torque operation. This pre-cushioning ensures reliable power transmission. However, the spring is designed with sufficient compliance that when foreign objects or excessive loads are encountered, the cushioning capacity is exceeded, allowing the couplings to slide and disengage, thus protecting the system from foreign object interference.
Solution Approach 2:
The spring mechanism converts the harmful effect of foreign object interference into a beneficial protective action. When foreign objects cause excessive loads, the spring force becomes insufficient to maintain engagement, allowing the spline couplings to slide and disengage. This converts the potentially catastrophic foreign object interference into a controlled disengagement event that protects the drive shaft assembly from damage.
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 assembly effectively reduces excessive load application to the supercharger and engine components, maintaining operational balance and preventing interference, while allowing temporary disconnection when high loads are encountered.
Implementation Method 1
The spring is mounted on the shaft adjacent to the first spline coupling and exerts a spring force against the first spline coupling that biases the first spline coupling into engagement with the second spline coupling
Implementation Method 2
When a rotational load applied to the first spline coupling exceeds a frictional force defined between the plurality of first teeth and the plurality of second teeth, then the interface between the plurality of first teeth and the plurality of second teeth converts the rotational load into a linear load along the longitudinal axis
Data Source
AI summary
A drive shaft assembly for a supercharger is provided. The drive shaft assembly includes a shaft extending along a longitudinal axis, a spline coupling mounted on the shaft, and a spring mounted on the shaft adjacent to the spline coupling. The spline coupling includes a first face spline with first teeth and a second face spline with second teeth which are configured to engage with the first teeth. The first face spline and the second face spline are biased into engagement by the spring. When a rotational load applied to the first face spline is sufficiently high, the first face spline disengages from the second face spline such that the first face spline and second face spline can rotate at different rates.