Torque-Limiting Disk Coupling for Surge Protection in Shaft Systems
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Solution Overview
Problem
Power generation systems face damage during surges due to excessive torque, which existing methods like scaling up the shaft system or using active actuators fail to prevent effectively, leading to increased manufacturing costs and reduced transmission efficiency.
Innovation Solution
A power transmission apparatus with a connection part that includes a portion decreasing and then increasing in diameter, allowing the connection between two disk parts to be broken in emergency situations, thereby preventing excessive torque from being transmitted and protecting the shaft system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shaft system is scaled up to prevent damage during surge, then the reliability of the shaft system improves, but the manufacturing cost and device complexity increase
Solution Approach 1:
The connection part is divided into multiple sections with varying diameters along its longitudinal direction, creating a segmented structure. This segmentation allows different portions to serve different functions: larger diameter sections provide strength for normal operation, while smaller diameter sections create predetermined weak points that can fail safely during surge events, protecting the overall shaft system without requiring complete system scaling.
Solution Approach 2:
The connection part employs local quality variation through its non-uniform diameter profile. Specific localized regions have reduced diameters to create controlled weak points, while other regions maintain larger diameters for structural integrity. This local differentiation allows the system to be designed for controlled failure at specific locations rather than requiring uniform strengthening of the entire shaft system.
2Reliability
If the shaft system is scaled up to prevent damage during surge, then the reliability of the shaft system improves, but the manufacturing cost increases
Solution Approach 1:
The connection part is divided into multiple sections with varying diameters along its longitudinal direction, creating a segmented structure. This segmentation allows different portions to serve different functions: larger diameter sections provide strength for normal operation, while smaller diameter sections create predetermined weak points that can fail safely during surge events, protecting the overall shaft system without requiring complete system scaling.
Solution Approach 2:
The connection part employs local quality variation through its non-uniform diameter profile. Specific localized regions have reduced diameters to create controlled weak points, while other regions maintain larger diameters for structural integrity. This local differentiation allows the system to be designed for controlled failure at specific locations rather than requiring uniform strengthening of the entire shaft system.
3Reliability
If the shaft system is enlarged to prevent damage during surge, then the reliability improves, but the power transmission efficiency decreases
Solution Approach 1:
The connection part is divided into multiple sections with varying diameters along its longitudinal direction, creating a segmented structure. This segmentation allows different portions to serve different functions: larger diameter sections provide strength for normal operation, while smaller diameter sections create predetermined weak points that can fail safely during surge events, protecting the overall shaft system without requiring complete system scaling.
Solution Approach 2:
The connection part employs local quality variation through its non-uniform diameter profile. Specific localized regions have reduced diameters to create controlled weak points, while other regions maintain larger diameters for structural integrity. This local differentiation allows the system to be designed for controlled failure at specific locations rather than requiring uniform strengthening of the entire shaft system.
4Reliability
If an active actuator is used to separate shafts during surge, then the reliability improves, but the response time is insufficient (50 ms delay)
Solution Approach 1:
The connection part is pre-designed with specific geometric features (reduced diameter sections) that create predetermined weak points. These structural characteristics are built into the component before operation, so that when surge occurs, the failure mechanism is already prepared and will activate automatically based on the physical conditions, eliminating the need for real-time detection and actuation delays.
Solution Approach 2:
The connection part automatically responds to surge conditions through its own structural design. The varying diameter profile causes stress concentration at specific locations during overload, leading to automatic failure at the predetermined weak points without requiring external sensors, control systems, or active actuators. The structure serves its own protection function.
Data Source
AI summary
A power transmission apparatus for transmitting power generated by a power generation apparatus to a generator and a power generation system including the same are provided. The power transmission apparatus for transmitting power generated by the power generation apparatus to the generator may include a first disk part connected to one of the power generation apparatus and the generator, a second disk part connected to the other one of the power generation apparatus and the generator and disposed on a rear side of the first disk part, and a connection part configured to connect the first disk part and the second disk part and include a portion that decreases and then increases in diameter along a longitudinal direction.