Tapered Shaft-to-Roller Coupling for Fast Indexed Alignment
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Solution Overview
Problem
Existing connections between transmission shafts and rollers are inefficient, leading to reduced processing efficiency, increased energy consumption, and higher costs due to downtime for replacement and alignment issues.
Innovation Solution
A pair of connectable portions with a male portion on the transmission shaft or roller and a complementary female portion on the other, 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 to connect the transmission shaft and roller, then torque transmission efficiency is improved, but the time required for roller replacement and alignment increases
Solution Approach 1:
The connection is segmented into a male portion on the transmission shaft and a complementary female portion on the roller, allowing independent replacement of the roller while maintaining the connection interface. This segmentation enables rapid roller replacement without affecting the transmission shaft, resolving the time loss contradiction while preserving torque transmission efficiency through the tapered friction connection.
Solution Approach 2:
The male and female portions are pre-configured with complementary tapered geometries and non-circular cross-sections before assembly. The non-circular cross-section includes predetermined alignment features that automatically guide correct radial alignment during insertion, eliminating the need for time-consuming alignment adjustments after roller replacement, thus reducing replacement time while maintaining accurate positioning for efficient torque transmission.
2Ease of operation
If the male portion has a circular cross-section, then ease of insertion is improved, but alignment precision with respect to another roller deteriorates
Solution Approach 1:
The male portion employs a non-circular cross-section with asymmetric features including flats, ridges, or keyed portions that provide predetermined alignment references. This asymmetric geometry maintains ease of insertion through the tapered friction fit while simultaneously ensuring precise radial alignment with other rollers by preventing rotation to incorrect positions, thus resolving the contradiction between insertion ease and alignment precision.
3Loss of energy
If the connecting portions are tightly connected to ensure efficient torque transmission, then torque transmission efficiency is improved, but the complexity of connection and disconnection increases
Solution Approach 1:
The connection utilizes a dynamic friction-based tapered interface where the friction force is sufficient to transmit torque efficiently during operation, but allows for controlled sliding and disengagement when force is applied. The non-circular cross-section with alignment features provides stable positioning during operation while enabling straightforward insertion and removal, thus maintaining high torque transmission efficiency without excessive connection complexity.
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 solution enables rapid and efficient removal and mounting of rollers, reduces wear, and enhances torque transfer efficiency, minimizing downtime and operational costs while ensuring accurate alignment.
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)
Data Source
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.