Tarp System Flexible Drive Shaft Motor Envelope
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Solution Overview
Problem
Existing tarp systems for trailers and railcars face challenges in fitting within regulatory envelope restrictions due to the bulky size of motors and gearboxes, which often exceed maximum allowable dimensions and struggle with torque reliability.
Innovation Solution
A tarp system incorporating a universal joint connector or flexible torque shaft within a bent enclosure, which includes a motor and knuckle arm assembly, minimizes the overall envelope by positioning the motor closer to the center and using a flexible drive shaft to operate the tarp, allowing for efficient operation within regulatory constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a motor is directly attached to the front of the axle, then the tarp system can be powered to operate automatically, but the motor becomes bulky and exceeds the regulatory envelope restrictions
Solution Approach 1:
The motor is repositioned from the front corner to the top surface of the container, utilizing vertical space rather than horizontal corner space. This dimensional relocation allows the motor to remain outside the regulatory envelope while still providing power to the tarp system through a driveshaft connection.
Solution Approach 2:
A driveshaft serves as an intermediary component, transmitting mechanical power from the motor (located on the top surface) to the axle (at the front corner). This intermediary allows the motor and axle to be separated in space, enabling the motor to be positioned outside the envelope while still driving the tarp mechanism.
2Volume of moving object
If multiple gearboxes are used to reduce motor size, then the motor becomes smaller, but the gearboxes themselves exceed the maximum allowable envelope and create reliability issues with torque handling
Solution Approach 1:
The gearbox component is extracted and eliminated from the system. Instead of using gear reduction, the motor operates directly at the required speed and torque conditions, simplifying the power transmission system and removing the reliability issues associated with multiple gearboxes.
3Volume of moving object
If the motor is positioned to minimize the envelope, then the tarp system fits within regulatory restrictions, but space becomes extremely limited for component placement
Solution Approach 1:
Components are arranged in three-dimensional space utilizing the top surface and vertical clearance above the container, rather than being constrained to the horizontal plane at the front corner. This allows the motor and driveshaft to be positioned to minimize the envelope footprint while maintaining adequate spacing for component installation and maintenance.
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 tarp systems to operate within tight space restrictions while maintaining reliability and efficiency, ensuring compliance with regulatory envelopes and facilitating safe and efficient tarp operation without manual handling.
Implementation Method 1
A flexible torque shaft may be used inside the enclosure. The flexible torque shaft may include a flexible portion within the enclosure between a rigid first end and a rigid second end.
Implementation Method 2
A universal joint connector may be used within the enclosure instead of the flexible torque shaft.
Implementation Method 3
A set of bearings can surround the ends of a universal joint connector or flexible torque shaft to facilitate rotation of the shaft relative to the enclosure.
Data Source
Figure 1
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Figure 3~4
AI summary
A tarp system (10) with a pivoting arm assembly (18) having a housing (22) associated with a motor (24) and with a bent enclosure (36) with a flexible drive shaft (25) substantially within the enclosure (36), such as an extruded tube. The flexible drive shaft may be a flexible torque shaft or a universal joint connector. A first end (32) of the flexible drive shaft may be used in conjunction with the motor (24), preferably mounted away from the bend (36) in the enclosure (36) to minimize the envelope of the tarp system (10) around a container (12) of a trailer or rail car. A second end (44) of the flexible torque shaft or universal joint connector is attached to an axle shaft (28) for a roller or the like that is used in conjunction with a tarp.