Split Flange Coupling for Misalignment Without Lubrication
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Solution Overview
Problem
Grid couplings face limitations in accommodating misalignment and require frequent maintenance due to lubrication needs and susceptibility to contamination, leading to increased operational costs and complexity.
Innovation Solution
The use of a split flange assembly with resilient elements and non-lubricated design, allowing for larger misalignment tolerance and reduced maintenance, featuring asymmetrically spaced splines and additional fasteners for enhanced torsional strength and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a grid coupling uses lubrication to reduce friction at interfaces, then friction is reduced and operation is smoother, but the coupling becomes susceptible to contamination and requires periodic maintenance
Solution Approach 1:
The patent removes the lubrication system entirely from the coupling design. The grid elements operate dry without any lubricant, eliminating the housing, seals, and lubrication application systems. This extraction of the lubrication function resolves the contradiction by achieving smooth operation through alternative means (precision fitting and material selection) while completely eliminating contamination susceptibility.
Solution Approach 2:
The coupling is designed to be maintenance-free and self-sufficient. The grid elements are constructed with built-in features such as oil holes and channels that allow self-lubrication through the grid material itself, or operate entirely dry without external lubrication. This self-service approach eliminates the need for periodic lubrication maintenance while maintaining smooth operation.
2Strength
If a grid coupling is designed with tight tolerances to accommodate minimal misalignment, then torque transmission is improved, but the coupling cannot handle parallel shaft misalignment greater than about 0.5 degrees
Solution Approach 1:
The patent employs grid elements with flexible, dynamic characteristics that can adapt to misalignment conditions. The grid elements are designed with inherent flexibility allowing them to bend and conform to angular and parallel misalignment between shafts while maintaining torque transmission. This dynamic design enables the coupling to handle misalignment greater than 0.5 degrees without compromising torque capacity.
Solution Approach 2:
The invention changes the geometric parameters of the grid elements, including their cross-sectional shape, thickness distribution, and positioning relative to the hubs. These parameter changes optimize the grid elements to simultaneously transmit high torque and accommodate significant misalignment. The grid elements may feature variable thickness or asymmetric cross-sections that provide both strength and flexibility.
3Reliability
If radial seals are installed on hub necks to prevent contamination, then sealing is improved, but hub removal is required for installation and the seals may be damaged during installation
Solution Approach 1:
The patent completely removes the radial seal system from the coupling design. By eliminating the need for lubrication and enclosed housing, the hubs can remain exposed without seals. This extraction resolves the contradiction by maintaining reliability through alternative means (dry operation without contamination) while eliminating installation complexity associated with seal fitting.
4Strength
If hubs are coupled onto rotating shafts using heated interference fit, then strong mechanical connection is achieved, but realignment during reinstallation is especially time consuming
Solution Approach 1:
The patent segments the coupling into modular components including the hubs, grid elements, and shaft interfaces. This segmentation allows each component to be independently designed and assembled. The hubs can be fitted to shafts with simplified alignment procedures due to the modular nature of the components, reducing reinstallation time while maintaining connection strength through optimized interface design.
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 solution increases torsional holding power by 146% and reduces maintenance costs by 65%, accommodating larger misalignments and eliminating the need for lubrication, while simplifying installation and reducing the weight and cost of the coupling.
Implementation Method 1
Grid couplings are uniquely configured to reduce vibration by as much as 30%, and to cushion shock loads
Implementation Method 2
At least one resilient element is disposed in the gap in abutting relation to the first and second annular flanges
Data Source
AI summary
A coupling includes first and second annular flanges in spaced relation across a gap. At least one resilient element is disposed in the gap in abutting relation to the first and second annular flanges. A first plurality of fasteners extends from the first annular flange, through the at least one resilient element, to the second annular flange, and a second plurality of fasteners extends from the second annular flange, through the at least one resilient element, to the first annular flange. Fasteners in the first plurality of fasteners is disposed in alternating fashion with fasteners in the second plurality of fasteners.