Torsionally Elastic Coupling With Elastomer-Embedded Wear Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current torsionally flexible couplings face challenges in accurately detecting wear, which can lead to excessive play and affect the reliability of the drive system, requiring complex inspection methods like visual or strobe sensor-based approaches.
Innovation Solution
Integration of a switching element and a transmitter, partially embedded in the elastomer, which emits radio signals, visible light, or audible signals when wear limits are reached, allowing for active and passive monitoring of wear conditions, enabling more efficient and reliable detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection or strobe sensor methods are used to detect wear, then wear can be detected, but the inspection methods become complex and require system idle time or additional sensors
Solution Approach 1:
The patent combines the wear detection function with the existing elastomer component by integrating a conductive element and switching element directly into the elastomer structure. This merging eliminates the need for separate inspection systems (visual inspection procedures or external strobe sensors), thereby reducing device complexity while maintaining wear detection capability
Solution Approach 2:
The elastomer component performs dual functions: it transmits torque mechanically and simultaneously monitors its own wear condition through the integrated switching element. The wear detection system is self-contained within the elastomer, eliminating the need for external monitoring equipment or complex inspection procedures
2Reliability
If a stationary measuring sensor is used to detect circuit impairment, then wear can be detected, but the system requires additional external sensors and complex circuit arrangements
Solution Approach 1:
The patent merges the wear detection functionality into the elastomer component itself by integrating the conductive element and switching element within the elastomer structure. This eliminates the need for separate stationary measuring sensors and complex external circuit arrangements, simplifying the overall system while maintaining reliable wear detection
Solution Approach 2:
The conductive element embedded in the elastomer serves as an intermediary that naturally follows the wear pattern of the elastomer. As the elastomer wears, the conductive element's position changes, automatically triggering the switching element to signal wear condition, thereby providing reliable detection without complex external sensing
3Device complexity
If the switching element is integrated into the elastomer, then wear detection is improved and device complexity is reduced, but the manufacturing of the elastomer becomes more complex
Solution Approach 1:
The patent utilizes 3D printing technology to manufacture the elastomer with integrated conductive and switching elements. This additive manufacturing approach allows for the direct incorporation of complex internal structures (conductive elements and switching elements) during the elastomer fabrication process itself, eliminating the need for separate assembly steps and making the integrated design manufacturable
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
This solution enhances wear detection accuracy and reliability, reducing the need for complex inspection methods and ensuring safe and reliable operation by providing timely maintenance alerts.
Implementation Method 1
the transmitter can emit electromagnetic waves in a frequency range intended for radio signals
Implementation Method 2
an illuminant such as a lamp or LED can be attached to the clutch, preferably externally, and can, for example, light up or flash when the wear limit is reached
Implementation Method 3
the transmitter can be designed as a loudspeaker to provide an acoustic signal when the wear limit is reached. In this case, the transmitter can emit audible sound waves
Implementation Method 4
Torsionally flexible couplings use elastomers to dampen torque and compensate for misalignments of the connected rotational axes
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a rotationally elastic coupling (1), wherein the rotationally elastic coupling (1) has a first coupling part (11) with elastomers (2), wherein the elastomers (2) are arranged in the first coupling part (11) in such a way that the elastomers (2) serve to transfer a force onto a second coupling part (12) when the first coupling part (11) and the second coupling part (12) are connected to one another. In order to improve the identification of wear, it is proposed that the rotationally elastic coupling (1) has a switching element (5), wherein the switching element (5) is arranged at least in part in a first elastomer (21) of the elastomers (2). The invention also relates to a method for producing a first elastomer (21) for a rotationally elastic coupling (1) of this kind, wherein the first elastomer (21) is printed using a 3D printer. The invention further relates to a method for identifying a wear state for a rotationally elastic coupling (1) of this kind, wherein a switching action of the switching element (5), which is caused by wear of the elastomer (2), serves to identify a wear limit.