Tool-less Quick-Disconnect Power Coupling Assembly
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Solution Overview
Problem
Existing power transmission couplings are difficult to quickly engage and disengage without tools, requiring precise alignment and tight tolerances, which complicates servicing and increases operator effort.
Innovation Solution
A power transmission coupling assembly using smooth diameter mating surfaces and a single torque transmitting member, with a locking mechanism and ball bearings, allowing for easy engagement and disengagement without tools, and maintaining secure power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If linear splined engagement mating surfaces are used, then secure power transmission is achieved, but the coupling becomes difficult to engage and disengage without tools
Solution Approach 1:
The coupling is divided into two separate hubs (drive shaft hub and driven shaft hub) that can be independently assembled and disassembled. Each hub has its own engagement features that work together, allowing the coupling to be split into manageable sections for easy tool-free assembly and disassembly while maintaining secure power transmission when engaged.
Solution Approach 2:
A single torque transmitting member acts as an intermediary element between the drive shaft hub and driven shaft hub. This intermediate component facilitates the connection and disconnection process, enabling tool-free operation while ensuring reliable torque transmission during engagement.
2Reliability
If tight tolerances are used between mating surfaces, then vibration is eliminated, but manufacturing complexity and cost increase
Solution Approach 1:
The engagement surfaces incorporate curved or tapered geometries rather than flat linear surfaces. This curvature provides self-centering action during assembly, automatically aligning the mating surfaces and eliminating vibration without requiring tight manufacturing tolerances. The curved surfaces guide the hubs into proper alignment as they engage.
Solution Approach 2:
The design changes the geometric parameters of the engagement surfaces from linear to curved/tapered profiles. This parameter change transforms the engagement mechanism from one requiring precise alignment to one that self-aligns through geometric guidance, reducing manufacturing complexity while maintaining vibration-free operation.
3Power
If multiple splines are used for torque transmission, then power transmission capacity increases, but the coupling becomes more complex and time-consuming to assemble
Solution Approach 1:
Multiple spline functions are merged into a single integrated torque transmitting member. This consolidated component performs the torque transmission function that would otherwise require multiple separate splines, reducing the number of parts and simplifying the assembly process to a single engagement action while maintaining adequate power transmission capacity.
Solution Approach 2:
The single torque transmitting member is designed to perform multiple functions: it transmits torque, provides alignment guidance, and enables the quick-connect/disconnect mechanism. This multi-functional design eliminates the need for separate components for each function, reducing overall coupling complexity.
4Reliability
If radial grooves interrupt the splines, then hub retention is achieved, but misalignment causes considerable difficulty in completing connection
Solution Approach 1:
The curved engagement surfaces perform preliminary alignment action before the hubs fully engage. This preliminary self-centering action occurs automatically as the hubs approach each other, ensuring they are properly aligned before the final connection is made, thereby eliminating misalignment difficulties even with retained hub features.
Solution Approach 2:
The curved/tapered engagement surfaces provide geometric guidance that compensates for any interruptions caused by retention features like radial grooves. The curvature guides the hubs into proper alignment throughout the engagement process, ensuring smooth connection completion despite the presence of hub retention mechanisms.
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
Enables quick and tool-free connection/disconnection of drive and driven shafts, reducing operator effort and downtime, while maintaining effective power transmission with reduced manufacturing costs and complexity.
Implementation Method 1
a plurality of ball bearings disposed within the locking mechanism and in engagement with the tapered surface, the ball bearings movable along the tapered surface to urge the driven shaft hub into engagement with the drive shaft hub
Implementation Method 2
a spring engaged with the locking mechanism to bias the locking mechanism to maintain the engaged configuration
Data Source
AI summary
A power transmission coupling that includes a drive shaft hub selectively connectable to a driven shaft hub. The drive shaft hub includes a number of ball bearings disposed within bores in the drive shaft that are selectively engageable within a groove disposed on the driven hub. The bearings are selectively locked within the groove by a sleeve movable disposed around the drive hub over the bearings. The drive hub also includes a key secured thereto that is selectively received within notches or apertures formed in the driven hub to mechanically engage the drive hub with the driven hub for effective power transmission via the coupling.