Telescoping Plug-In Coupling for Sealed Drive Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plug-in couplings for drives, particularly in rail vehicles, require special assembly openings that compromise housing stability and are difficult to seal, especially in harsh environments.
Innovation Solution
A plug-in coupling system where the drive shaft and output shaft are aligned axially and connected via rotatably fixed coupling portions that can be mechanically plugged together, allowing torque transmission while compensating for axial and angular offsets, and featuring a telescoping design that eliminates the need for assembly openings and provides a sealing function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If assembly openings are provided in the housing for coupling assembly, then the coupling can be assembled, but the housing structure stability is compromised and sealing becomes difficult
Solution Approach 1:
The coupling is divided into two separate coupling portions (first coupling portion on drive shaft, second coupling portion on output shaft) that can be assembled independently and then connected. This segmentation allows the coupling to be assembled without creating openings in the housing structure, as each portion can be mounted separately and then joined through the coupling mechanism.
Solution Approach 2:
The coupling portions are designed to be nested or telescoped together, with one coupling portion fitting into or alongside the other. This nesting arrangement allows the coupling to be assembled within the existing housing structure without requiring additional assembly openings, thereby maintaining housing stability while enabling coupling assembly.
2Ease of manufacture
If assembly openings are provided in the housing for coupling assembly, then the coupling can be assembled, but sealing effectiveness deteriorates in harsh environments
Solution Approach 1:
By segmenting the coupling into two separate portions that are assembled independently, the design eliminates the need for large assembly openings in the housing. This reduces the sealing surface area required and minimizes potential sealing failure points, thereby improving sealing effectiveness in harsh environments.
Solution Approach 2:
The coupling portions incorporate sealing elements such as lip seals or labyrinth seals that can flex and adapt to minor misalignments and movements. These sealing mechanisms maintain effective sealing without requiring rigid, large openings in the housing, thus improving reliability in harsh environments while enabling coupling assembly.
3Ease of manufacture
If traditional coupling assembly methods are used with assembly openings, then coupling can be assembled, but assembly time increases
Solution Approach 1:
The coupling portions are pre-assembled onto their respective shafts (drive shaft and output shaft) before final coupling. This preliminary action allows the coupling portions to be prepared in advance and then quickly connected to each other, significantly reducing the overall assembly time compared to traditional methods that require opening the housing and assembling everything in place.
Solution Approach 2:
The coupling is segmented into two independently assembleable portions that can be prepared separately and then quickly joined. This segmentation enables parallel assembly processes and eliminates the need for time-consuming housing opening and closing operations, thereby reducing total assembly time while maintaining ease of manufacture.
Data Source
AI summary
A drive includes at least one motor with a drive shaft and at least one output shaft which is in particular mechanically connected to a gear. The drive shaft and the output shaft are aligned substantially axially. The drive shaft and the output shaft each have a coupling portion through which a torque can be transmitted from the drive shaft to the output shaft by mechanical coupling. Each coupling portion is connected to the shaft thereof for rotation therewith and the coupling portions can be mechanically coupled by being axially plugged together.