Tapered Shaft-to-Roller Coupling for Fast Indexed Torque Transfer
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Solution Overview
Problem
Current connections between transmission shafts and rollers in industries like tobacco crimping are inefficient, leading to high energy consumption, frequent downtime for maintenance, and difficulties in aligning rollers due to wear and fouling, especially with fine-scale cooperating patterns.
Innovation Solution
A pair of connectable portions with a male portion on the transmission shaft and a complementary female portion on the roller, featuring a non-circular cross-section and inward taper, allowing for rapid connection and disconnection, efficient torque transmission, and indexed positioning for accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a Morse taper connection is used with a central screw, then torque transmission efficiency is improved, but the time required for assembly and disassembly increases
Solution Approach 1:
The connection is divided into two functional parts: a Morse taper portion for torque transmission and a separate quick-release mechanism (latch or lever) for rapid assembly and disassembly. This segmentation allows each part to optimize its specific function without compromising the other.
Solution Approach 2:
A central latch or lever acts as an intermediary mechanism that controls the engagement and disengagement of the Morse taper connection. This intermediary allows quick release without requiring manual manipulation of the taper itself, reducing assembly time while maintaining torque transmission efficiency.
2Reliability
If rollers are frequently removed and replaced for maintenance, then roller wear and fouling are addressed, but processing downtime increases
Solution Approach 1:
The quick-release mechanism is pre-configured to enable rapid disengagement of rollers without requiring complex manipulation or special tools. This preliminary design feature ensures that when maintenance is needed, rollers can be quickly removed and replaced, minimizing processing downtime while maintaining roller reliability.
3Manufacturing precision
If fine-scale cooperating patterns are used on roller surfaces, then processing precision is improved, but susceptibility to wear and fouling increases
Solution Approach 1:
The rollers with fine-scale patterns are designed as replaceable, relatively inexpensive components that can be quickly swapped out when worn or fouled. This approach treats the precision rollers as consumable parts rather than permanent fixtures, allowing frequent replacement without significant cost or downtime, thus maintaining processing precision while managing wear and fouling.
4Manufacturing precision
If radial alignment of rollers is carefully adjusted, then processing accuracy is improved, but adjustment time and complexity increase
Solution Approach 1:
The quick-release mechanism incorporates asymmetric features that guide and constrain roller positioning during installation. This asymmetric design inherently promotes correct radial alignment without requiring complex adjustment procedures, reducing both time and complexity while maintaining alignment accuracy.
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
Facilitates rapid and efficient mounting and removal of rollers, reduces energy consumption, and minimizes misalignment issues, thereby decreasing downtime and maintenance costs while ensuring precise alignment and efficient processing.
Implementation Method 1
Frictional interference between the outer surface of the male portion and the inner surface of the female portion allows torque to be transmitted from the first body to the second body (or vice versa)
Implementation Method 2
The male portion tapers inwardly from a proximal end to a distal end... Frictional interference between the outer surface of the male portion and the inner surface of the female portion allows torque to be transmitted... The efficiency of transmission of torque is directly related to the application of a compressive force between the male and female portions
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A transmission shaft and a roller comprising a pair of connectable portions (M, F) for connecting a transmission shaft (5, 8) and a roller (4, 7) to be driven by torque exerted through the transmission shaft (5, 8). The pair of connectable portions (M, F) comprise a male portion (M) provided on one of the transmission shaft (5, 8) and roller (4, 7) and a complementary female portion (F) provided on the other of the roller (4, 7) and transmission shaft (5, 8). The male portion (M) has a longitudinal axis of rotation (X) and tapers inwardly from a proximal end to a distal end. The male portion (M) has a non-circular cross section.