Superhard Torque Coupling Assembly for Corrosive Wear Resistance
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Solution Overview
Problem
Existing force coupling assemblies in mechanical applications, such as subterranean drilling systems, face challenges in withstanding torque and maintaining durability in caustic and corrosive environments, leading to increased wear and maintenance costs due to deflection of rotating components.
Innovation Solution
The use of superhard contact elements, such as polycrystalline diamond compact (PDC) layers on cemented tungsten carbide substrates, in torque coupling assemblies with annular or polygonal ring configurations that maintain stationary engagement under load, transferring torque between laterally or radially arranged rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact elements are used in torque coupling assemblies, then the assembly can transfer torque between rotating components, but the contact elements experience increased wear and reduced durability in caustic and corrosive environments
Solution Approach 1:
The patent applies composite materials by coating conventional contact elements with superhard materials such as diamond-like carbon (DLC), cubic boron nitride (CBN), or polycrystalline diamond. These composite structures combine the mechanical properties of the base material with the extreme wear and corrosion resistance of the superhard coating, enabling the contact elements to withstand caustic and corrosive fluids while maintaining torque transfer capability.
Solution Approach 2:
The patent changes the surface hardness parameter of the contact elements by applying superhard coatings with hardness values exceeding 40 GPa, compared to typical conventional materials. This parameter change dramatically reduces wear rates and improves resistance to caustic and corrosive environments, directly addressing the reliability issue.
2Adaptability or versatility
If the output shaft is allowed to deflect at various angles relative to the axis of rotation, then the system can accommodate misalignment, but additional forces and loads are applied to the force couplings as they become displaced from the central axis
Solution Approach 1:
The patent employs spherical contact elements that can dynamically adjust their position and orientation as the output shaft deflects. The spherical geometry allows the contact elements to self-align and redistribute loads, accommodating angular misalignment while maintaining optimal contact conditions and reducing excessive forces on the force couplings.
Solution Approach 2:
The patent uses spherical or curved contact surfaces instead of flat or rigid geometries. The spherical shape enables the contact elements to accommodate shaft deflection and angular misalignment by rolling or pivoting, thereby maintaining stable contact and reducing peak loads even when displaced from the central axis.
3Reliability
If superhard contact elements are used to reduce wear, then the durability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent segments the contact element into a conventional base material and a superhard coating layer. This segmentation allows the bulk material to provide structural integrity and mechanical properties, while only the surface layer requires superhard material properties. The coating can be applied using established techniques such as physical vapor deposition (PVD), chemical vapor deposition (CVD), or thermal spray, making the manufacturing process more feasible than creating entirely superhard components.
Data Source
AI summary
Force coupling or torque coupling assemblies, apparatuses, systems, and methods include assemblies that each include superhard contact elements. At least some of the superhard contact elements may be configured to remain in contact with each other when a force is applied between the assemblies.