Wave Spline Torque Coupler for Low-Backlash High-Torque Assembly
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Solution Overview
Problem
Traditional coupling devices are often bulky, expensive, prone to backlash, require excessive force for assembly, and can fail in high-torque or high-vibration environments.
Innovation Solution
A torque transferring coupler (TTC) featuring an inner cylinder with radially disposed wave splines and an outer cylinder with axially disposed wave splines, allowing for a secure, low-backlash connection with reduced manufacturing tolerance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupling devices (flange coupling, set screw, keyway, traditional spline, shrink fit, or press fit) are used, then the coupling can be manufactured and assembled, but they become bulky, expensive, prone to backlash, require excessive force to secure, and can break or come undone during use
Solution Approach 1:
The patent applies curved wave spline profiles instead of traditional straight or angular spline forms. The wave splines on the inner and outer cylinders have smoothly curved surfaces that interlock, distributing stress more evenly and eliminating backlash while maintaining compact dimensions. This curvature-based approach resolves the contradiction by providing reliable torque transfer without the bulk and complexity of traditional coupling structures.
Solution Approach 2:
The wave spline coupling allows for dynamic adjustment and self-centering during operation. The flexible wave profiles can accommodate minor misalignments and vibrations, maintaining reliable connection without requiring overly complex rigid structures or excessive assembly force, thus improving reliability while keeping the device simple.
2Ease of operation
If traditional coupling devices are used, then the coupling can be assembled, but they require excessive force to secure the coupling
Solution Approach 1:
The curved wave spline surfaces provide gradual engagement during assembly, allowing the inner and outer cylinders to interlock smoothly without requiring excessive assembly force. The curved profiles distribute the assembly load evenly across the contact surfaces, making the coupling easy to assemble while maintaining secure connection.
3Ease of manufacture
If traditional coupling devices are used, then the coupling can be manufactured, but they are expensive to manufacture
Solution Approach 1:
The wave spline profiles can be manufactured using standard curving or forming processes rather than requiring complex precision machining of traditional spline teeth. The curved surfaces are more tolerant to manufacturing variations, reducing the need for expensive high-precision machining while maintaining functional performance, thus lowering manufacturing costs.
Solution Approach 2:
The patent changes the geometric parameters from traditional rigid spline forms to flexible wave profiles, which can be produced more economically through forming, rolling, or casting processes. This parameter change allows manufacturing with lower precision requirements while maintaining the coupling's torque transfer capability, reducing overall manufacturing cost.
4Measurement precision
If traditional coupling devices are used, then the coupling can function, but they have excessive backlash
Solution Approach 1:
The curved wave spline surfaces provide continuous contact between the inner and outer cylinders, eliminating the gaps and clearance that cause backlash in traditional couplings. The smooth curved profiles ensure positive engagement without requiring complex preloading mechanisms or adjustment devices, achieving high positioning precision with simple structure.
Data Source
AI summary
A device includes an inner cylinder and an outer cylinder. The inner cylinder has a radial face including a first set of curved structures. The outer cylinder has an axial face including a second set of curved structures. A coupling is formed in response to a section of the outer cylinder disposed to surround a portion of the inner cylinder and the first set of curved structures of the inner cylinder disposed to interlock with the second set of curved structures of the outer cylinder.