German Intelligente Peripherien coupling Intelligente Peripherien model Intelligente Peripherien price

Intelligente Peripherien couplings are mechanical components used to connect two shafts (drive shaft and driven shaft) in different mechanisms, enabling them to rotate together to transmit torque. In high-speed, heavy-load power transmission, some couplings also provide buffering, vibration damping, and improved dynamic performance of the shaft system. A coupling consists of two halves, each connected to the drive shaft and driven shaft respectively. Generally, prime movers are connected to working machines via couplings.

Intelligente Peripherien coupling introduction

It consists of two hubs and a thin-walled metal tube, connected by either welding or bonding. Although many other materials are available, stainless steel and nickel are the most commonly used materials for the metal tube. Nickel tubes are produced using electrodeposition. This method first involves machining a solid mandrel into a corrugated shape, electroplating nickel onto the mandrel, and then chemically dissolving the mandrel to obtain a nickel bellows. This method allows precise control of the bellows wall thickness and can achieve thinner walls than those produced by other methods. These thin-walled bellows give the coupling high sensitivity and rapid response, making it ideal for applications in extremely small and precision instruments.

Intelligente Peripherien coupling structure composition

The input end of the coupling structure features a clamping hub design, where preload is generated by clamping screws to rigidly connect the power input shaft with the clamping hub. The output end features a taper lock design, where tightening screws preload a cone, causing the locking sleeve to expand and fit into the inner bore of the power output shaft, forming a unified connection. The center features a bellows structure, with both ends of the bellows adhesively bonded to the input and output ends.

Intelligente Peripherien coupling troubleshooting

Based on the coupling structure, the coupling transmits power to the power output shaft (gearbox shaft) via a taper lock fit, and to the power input shaft via a clamping hub. Power is transmitted between the clamping end and the taper lock end of the coupling through the bellows, which is adhesively bonded to the taper lock end and the clamping hub. The fault location is at the clamping hub and the bellows. Two pre-deformation slots are machined radially into the clamping hub. The slot width is approximately 2mm. On the side with the clamping screw, the slot is through in the diametrical direction but not fully open in the depth direction at the junction with the bellows, featuring a beveled cross-section. The other slot does not extend through radially, but its longitudinal junction with the bellows is also not fully open, featuring a beveled cross-section. During clamping, the clamping screws are tightened to the specified value using a torque wrench. The deformation of the clamping hub eliminates the clearance between the hole and the shaft to achieve clamping. As seen from the cross-sectional view, due to the presence of the two pre-deformation slots, the cross-section at this location is weaker, and deformation primarily occurs at these slots. The pre-deformation slot on the side with the clamping screw has the smallest cross-sectional area and is the weakest point. Permanent figure-eight deformation marks at its end indicate that the stress in this area during clamping is significant, exceeding the yield limit of super-hard aluminum. According to the stress distribution diagram, once the bevel gear box and main gearbox are assembled and clamped, the stress value at the adhesive interface of the pre-deformation slot on the clamping screw side is 164Mpa, with a deformation magnitude of 0.027mm. During launcher operation, the coupling is subjected to alternating composite stresses, resulting in even greater stress and deformation at this location. If minor defects such as voids, inclusions, or blemishes exist at the adhesive interface during manufacturing, micro-cracks will first form at defective areas within the region of maximum stress on the coupling's adhesive interface when the alternating stress exceeds the bond strength, creating a fatigue source. Due to stress concentration at the crack tip, the crack gradually propagates as the number of stress cycles increases and the duration of constant stress extends. As the crack spreads, the adhesive interface is progressively weakened. When the crack reaches a certain size, fatigue failure occurs. The coupling functioned normally during initial testing, but as usage time increased, the cracks gradually propagated. Even under low loads, the coupling eventually failed. The presence of stress at the adhesive joint is a potential hidden cause of failure. To avoid generating high stress in the clamping hub during clamping, annular grooves are typically cut into the clamping hub for stress relief.

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