Splined Shaft Coupling With Conical Self-Alignment
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Solution Overview
Problem
Existing methods for connecting the rotor shaft of a traction motor to the gearbox shaft in electric vehicles face challenges in achieving smooth rotational motion transfer while minimizing wear and manufacturing complexity, particularly due to the need for high precision alignment and additional components.
Innovation Solution
A system utilizing a splined connection combined with conical centering surfaces and a force applicator, such as a spring, to align the shafts, reducing the need for high precision manufacturing and improving alignment efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional shaft connection methods are used, then manufacturing precision requirements are high, but manufacturing complexity and cost increase
Solution Approach 1:
A conical centering arrangement with complementary conical surfaces acts as an intermediary mechanism between the two shafts. When axial force is applied, the conical surfaces generate radial centering forces that automatically align the shafts, eliminating the need for high-precision manufacturing while ensuring proper alignment through mechanical self-centering
Solution Approach 2:
The conical surfaces transform the axial force parameter into radial centering forces through geometric conversion. The taper angle of the conical surfaces determines the magnitude and direction of the centering forces, allowing adjustment of alignment characteristics by changing the geometric parameter of the conical surfaces
2Reliability
If high precision alignment is achieved, then shaft wear is reduced, but manufacturing cost increases
Solution Approach 1:
The conical centering arrangement performs preliminary alignment action before the shafts begin rotational operation. By applying axial force during assembly or operation, the conical surfaces generate radial forces that pre-position the shafts in correct alignment, preventing wear during subsequent operation without requiring high-precision manufacturing
Solution Approach 2:
The conical centering arrangement is self-adjusting and self-centering during operation. As the shafts experience axial loads during normal operation, the conical surfaces automatically generate the necessary radial forces to maintain alignment, allowing the system to self-correct and maintain optimal alignment without external intervention or high-precision manufacturing
3Measurement precision
If additional alignment components are added, then alignment accuracy improves, but device complexity increases
Solution Approach 1:
The conical centering surfaces are integrated directly into the shaft structures themselves, merging the alignment function with the existing shaft components. This eliminates the need for separate alignment components while achieving accurate alignment through the geometric relationship between the complementary conical surfaces
Solution Approach 2:
The conical surfaces serve multiple functions simultaneously: they provide mechanical support for axial loads, generate radial centering forces for alignment, and guide the relative positioning of the shafts. This multi-functionality achieves accurate alignment without adding dedicated alignment components
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 system ensures robust and efficient alignment of the shafts, minimizing wear and manufacturing costs by allowing for lower tolerance bearings and even lubricant distribution, while maintaining operational efficiency.
Implementation Method 1
the first conical surface is configured to engage with the second conical surface to form a conical centering arrangement configured to align a longitudinal axis of the first shaft with a longitudinal axis of the second shaft when an axial force is applied
Implementation Method 2
the force applicator comprises a spring, such as a leaf spring, a disc spring or a coil spring
Data Source
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AI summary
A system for coupling a first shaft (105) to a second shaft (135). Each shaft includes a set of splines and a conical surface. The sets of splines are configured to engage with each other and the conical surfaces are configured to engage with each other so as to improve the alignment between the first shaft and the second shaft when an axial force is applied to one of the shafts with a force applicator (150).