Torque-Limiting Coupler for Shaft Misalignment and Overload Protection
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Solution Overview
Problem
Electric motors in vehicles can apply excessive torque to components like camshaft phasers, causing unwanted stress and misalignment, which can lead to damage and increased wear.
Innovation Solution
A torque-limiting coupler system that includes an elastic member and a rigid frame, allowing angular displacement when torque exceeds a predetermined limit, thereby limiting torque transmission and accommodating misalignment between the electric motor shaft and the rotatable input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a rigid coupling is used between the electric motor shaft and the rotatable input, then torque transmission is efficient, but excessive torque causes damage and wear to components
Solution Approach 1:
The patent introduces a torque-limiting coupler as an intermediary device between the electric motor shaft and the rotatable input. This coupler includes a torque limiting mechanism that allows efficient torque transmission under normal conditions while automatically disengaging or slipping when torque exceeds a predetermined threshold, thereby protecting components from damage and wear
Solution Approach 2:
The torque-limiting coupler changes the torque transmission parameter dynamically. Under normal operating conditions, it maintains rigid coupling for efficient power transmission. When torque exceeds the threshold, it changes state to allow relative motion or disengagement, effectively limiting the maximum torque transmitted to protect downstream components
2Adaptability or versatility
If the electric motor is mounted to accommodate vehicle functions, then vehicle integration is achieved, but misalignment between the output shaft and rotatable input occurs
Solution Approach 1:
The torque-limiting coupler incorporates dynamic elements that allow for angular misalignment between the electric motor output shaft and the rotatable input. The coupler can accommodate varying angular positions through its torque-limiting mechanism, which maintains functional connection while allowing for misalignment, thus enabling flexible vehicle integration without requiring precise manufacturing alignment
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 system effectively limits torque to prevent damage and wear on vehicle components by allowing angular and misalignment compensation, ensuring safe and efficient operation of electric motors.
Implementation Method 1
an elastic member, configured to engage the other of the rotatable input or the output shaft of the electric motor, that engages the rigid frame such that the elastic member substantially maintains its shape and inhibits angular displacement between the rotatable input and the output shaft when an amount of torque received from the output shaft is below a predetermined torque limit, the elastic member changes shape permitting angular displacement between the rotatable input and the output shaft when an amount of torque received from the output shaft exceeds the predetermined torque limit
Data Source
AI summary
A torque-limiting coupler for connecting an electric motor to a rotatable input of a vehicle is provided, including: a rigid frame that is configured to be coupled to one of the rotatable input or an output shaft of the electric motor; and an elastic member, configured to engage the other of the rotatable input or the output shaft of the electric motor, that engages the rigid frame such that the elastic member substantially maintains its shape and inhibits angular displacement between the rotatable input and the output shaft when an amount of torque received from the output shaft is below a predetermined torque limit, the elastic member changes shape permitting angular displacement between the rotatable input and the output shaft when an amount of torque received from the output shaft exceeds the predetermined torque limit.