What types of couplings are available? What scenarios are they suitable for?
In the power transmission system of machinery and equipment, there are various types of couplings, and different types of couplings are suitable for different working scenarios due to their structural characteristics and performance differences. Choosing the right type of coupling is the key to ensuring the efficient and stable operation of the equipment. In this paper, we will systematically sort out the common types of couplings and analyze the typical scenarios of their respective adaptations.
First, rigid coupling: the first choice for high-precision and low-deviation scenarios
Rigid coupling is the simplest type of coupling, mainly through the rigid connection to transmit torque, almost no deviation compensation ability, suitable for the prime mover and the axis of the working machine is strictly aligned (the deviation is very small, usually radial deviation of ≤ 0.05mm, angular deviation of ≤ 0.1 °) and there is no violent vibration of the scenarios.
1. Flanged coupling: two half-couplings with flange are bolted together to form a solid structure and transmit large torque (up to tens of thousands of N.m.), suitable for low-speed, heavy-duty and high neutral requirements of the occasion, such as crusher of mining machinery, the main drive system of the rolling mill.
2. Sleeve coupling: through the sleeve and key or pin will be connected to the two shafts, compact structure, low cost, but the disassembly is inconvenient, mostly used for light load, low-speed small equipment, such as small pumps, fans drive system.
3. Clip shell coupling: composed of two semi-cylindrical clamping shell and bolts, easy to install and disassemble, without axial movement of the shaft system, suitable for smaller shaft diameter (usually ≤ 100mm), the transmission of medium torque occasions, such as machine tool feed drive system.
Second, the elastic coupling: vibration cushion and deviation compensation scenarios of the main force
elastic coupling through the elastic element (such as rubber, polyurethane, metal diaphragm, etc.) to transmit torque, with a certain degree of deviation compensation and vibration cushioning performance, is one of the most widely used type of industrial equipment, suitable for the existence of a slight mounting deviation or vibration of the scenario.
1. Rubber elastic coupling: rubber as the elastic element, with good vibration damping and axial, radial deviation compensation ability (radial deviation ≤ 0.5mm, angular deviation ≤ 1 °), low cost but poor resistance to high temperatures (usually ≤ 80 ℃ working temperature), for general-purpose machinery such as pumps, fans, compressors, etc.
2. Polyurethane coupling: the elastic element is polyurethane, wear resistance is better than rubber, transmission torque is larger, the working temperature range is wider (-30 ℃ ~ 100 ℃), suitable for textile machinery, printing machinery and other medium load and the need for a certain buffer equipment.
3. Diaphragm coupling: using metal diaphragm as the elastic element, no gap, high transmission accuracy (positioning accuracy up to ± 0.01mm), can compensate for angular and radial deviation (angular deviation ≤ 0.5 °, radial deviation ≤ 0.2mm), high temperature resistance, long life, suitable for high-precision transmission systems, such as CNC machine tools, spindle, servo motors and ball screws connection.
4. Bellows coupling: transfer torque through metal bellows, strong deviation compensation (angular deviation ≤ 1 °, radial deviation ≤ 0.5 mm), good rigidity, small inertia, suitable for high-speed operation equipment, such as centrifugal separator, precision test equipment transmission system.
Third, the safety coupling: overload protection demand scenarios of the guarantee
safety coupling in the transmission torque exceeds the rated value, will cut off the power transmission by slipping, fracture or disengagement, etc., to protect the equipment from overload damage, adapted to the existence of a sudden risk of overload scenarios.
1. Friction type safety coupling: rely on the friction between the friction plate to transmit torque, overload friction plate slippage, can automatically resume work, suitable for frequent startup, may be overloaded equipment, such as conveyors, mixers and so on.
2. Pin-type safety coupling: transfer torque through shear pins, overload pin breakage cut off the power, need to replace the pin to resume work, simple structure, low cost, applicable to not allow slipping but need to protect the overload occasions, such as crusher, pulverizer drive system.
3. Magnetic particle safety coupling: the use of magnetic powder magnetization characteristics of the torque transfer, can be adjusted through the excitation current to control the size of the torque transfer, overload, automatic slip, rapid response and no mechanical wear, suitable for precision machinery, automated production lines and other equipment that require high protection accuracy.
Fourth, the universal coupling: the right choice for large angular deviation scenarios
Universal couplings (cross-shaft universal couplings) can transmit torque under large angular deviation (the maximum angular deviation of a single section can be up to 35°~45°), and they are suitable for scenarios in which the two shafts are not co-linear and there is a large angular deviation.
1. Single cross shaft universal coupling: simple structure, but in the transmission of torque will produce additional dynamic load, suitable for low speed, short distance and angular deviation is not large occasions, such as automobile transmission shaft (and transmission and drive axle connection).
2. Double Cross Shaft Universal Coupling: connecting two single cross shaft universal joints through the intermediate shaft, it can eliminate the additional dynamic load, and is suitable for larger angular deviation and requires smooth transmission of the scene, such as the roller drive of the rolling mill, the slewing mechanism of construction machinery.
Fifth, special couplings: customized solutions for special working conditions
In addition to the above common types, there are also special couplings designed for special working conditions, adapted to a variety of complex environments and performance requirements.
1. High-temperature couplings: made of high-temperature-resistant materials (such as heat-resistant alloys and ceramics), with high-temperature-resistant rubber or metal bellows used as the elastic element, they are suitable for high-temperature environments in metallurgy and chemical industry (with operating temperatures of more than 300 degrees Celsius), such as the transmission system of steel converter.
2. Corrosion-resistant couplings: stainless steel, titanium alloy and other corrosion-resistant materials, the surface of the anticorrosion treatment, suitable for humid, dusty or corrosive media environment, such as chemical pumps, seawater desalination equipment drive system.
3. Miniature precision coupling: compact size (outer diameter usually ≤ 20mm), transfer torque is small but high precision, suitable for medical equipment, precision instruments, semiconductor equipment and other micro-drive systems, such as microscope focusing mechanism, chip detection equipment transmission components.
Sixth, the core principles of coupling type selection
When choosing the coupling type, need to combine the core needs of the scene comprehensive judgment: if the pursuit of high precision and good alignment, the priority of the rigid coupling; there are vibration and slight deviation, the elastic coupling is a better choice; there is a risk of overload scenarios must be equipped with safety couplings; the two axes need to use universal couplings when the angle of the deviation of the two axes is large; Special environmental conditions require special couplings. Only according to the specific scene of the torque size, speed, type of deviation, environmental conditions and other factors reasonable selection, in order to give full play to the performance advantages of the coupling, to protect the stable operation of the equipment.
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