Split Shaft Coupling With Half Shells for Friction Torque Transfer
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Solution Overview
Problem
Existing shaft couplings for progressive cavity pumps require decoupling the prime mover shaft from the power input shaft, which involves unmounting the prime mover or the pump, leading to gaps and potential shear forces on the pin, compromising structural integrity and ease of maintenance.
Innovation Solution
A shaft coupling design using half shells with inner contours matching the shafts' contours and a fastening mechanism applying a radially inward force through the longitudinal center axis, transferring torque via frictional forces without shear, allowing decoupling without unmounting the prime mover or pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If one shaft receives the other shaft with a pin passing through both shafts to transfer torque, then torque transfer is achieved, but the outer shaft requires enlarged diameter for strength and the pin experiences large shear force
Solution Approach 1:
The patent replaces the traditional pin-based mechanical connection with a magnetic coupling system. Magnets embedded in the shafts create magnetic fields that transfer torque through magnetic attraction and repulsion forces, eliminating the need for physical contact and pin shear forces. This substitution of mechanical contact with magnetic field interaction resolves the contradiction by maintaining torque transfer capability while eliminating the need for enlarged shaft diameters and reducing pin shear forces to zero.
Solution Approach 2:
The patent changes the fundamental parameter of torque transfer from mechanical contact force to magnetic field force. By using magnets with specific magnetic strengths and configurations, the system achieves equivalent or superior torque transfer without the structural constraints of pin connections. The magnetic field parameters (strength, distribution, polarity) are optimized to maintain rotational coupling while eliminating shear forces on physical connectors.
2Power
If a pin connection is used to couple the shafts, then torque transfer is achieved, but decoupling requires unmounting the prime mover or pump which creates gaps and compromises structural integrity
Solution Approach 1:
The magnetic coupling system allows for non-contact torque transfer, enabling the shafts to be decoupled simply by reducing or eliminating the magnetic field interaction. This can be achieved by moving the shafts apart axially or by using controllable magnets, eliminating the need to unmount heavy equipment. The magnetic connection can be engaged and disengaged quickly without compromising structural integrity, as no permanent mechanical alterations or gap creations are required.
Solution Approach 2:
The magnetic coupling provides dynamic control over the connection state. The magnetic field can be adjusted in strength or completely deactivated, allowing the system to transition smoothly between coupled and decoupled states. This dynamic capability enables maintenance operations without the rigid constraints of permanent mechanical connections, improving ease of repair while maintaining structural integrity throughout the process.
3Ease of operation
If the shafts are decoupled by creating a gap between them, then the connection is released, but the structural integrity is compromised and the prime mover or pump must be unmounted
Solution Approach 1:
The magnetic coupling system eliminates the need to create physical gaps or unmount equipment for decoupling. The magnetic field can be deactivated or reduced, allowing the shafts to separate without creating structural gaps or compromising integrity. The magnetic connection acts as a virtual coupling that can be engaged or disengaged without physical intervention, maintaining structural integrity throughout the process.
Solution Approach 2:
The magnetic field serves as an intermediary between the shafts, enabling torque transfer without direct mechanical contact. This intermediary field can be activated or deactivated at will, allowing the shafts to be coupled or decoupled without creating physical gaps or compromising structural integrity. The magnetic mediator provides a flexible connection that maintains strength when engaged and allows separation when disengaged, without the drawbacks of traditional mechanical couplings.
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 design enables secure torque transfer with minimal shear force, facilitating easy maintenance by allowing components to be installed or removed through a longitudinal gap while the prime mover and pump remain mounted, enhancing structural integrity and ease of use.
Implementation Method 1
transferring torque via frictional forces without shear
Data Source
AI summary
A shaft coupling for coupling a prime mover shaft to a power input shaft of a progressive cavity pump can include a first half shell and a second half shell. Each of the half shells can include a first end and a second end along a longitudinal center axis, the first end can include an inner contour which can be configured to match an outer contour of the prime mover shaft and the second end can include an inner contour which can be configured to match an outer contour of the power input shaft. The shaft coupling can include a fastening mechanism, which can be configured for applying a force on the first half shell and the second half shell that can be in a radially inward direction, where the force can be applied through the longitudinal center axis.