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COUPLINGS 16.14
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FIGURE 16.13 How the grid coupling accommodates misalignment. (Falk Corp.)
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FIGURE 16.14 Beam coupling. (Helical Products Corp.)
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and axial misalignment, as shown in Fig. 16.18. There is no relative rotation between the gear teeth, as in a normal gear set. Various tooth profiles (including crowned and/or barrel-shaped teeth) or changes in pressure angle allow for different misalignment, life, and load capacities. Straight-tooth couplings allow misalignment of 1 per gear mesh; with barrel-shaped teeth on the hub and straight teeth on the sleeve, 6 per mesh can be allowed. With perfect alignment, all the teeth in the coupling are in contact, and the load is evenly distributed among them. Misalignment concentrates the load on just a few teeth; the number of teeth under load is a function of misalignment and load. The greater the misalignment (angular and parallel), the fewer the number of teeth in contact and the higher the load per tooth. Barrel-shaped teeth distribute the load over a larger area per tooth and may allow a greater number of teeth to be in contact under misaligned conditions, as shown in Fig. 16.19. The two gear meshes can be separated by large distances, as shown in Fig. 16.20. In this case, two single-engagement couplings are connected by a floating shaft. For
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FIGURE 16.15 Cutaway view of diaphragm coupling assembly showing multiple convoluted diaphragms. (Zurn Industries, Inc., Mechanical Drives Div.)
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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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COUPLINGS 16.15
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FIGURE 16.16 Hydraulic coupling; cutaway shows oil forced between inner and outer tapered sleeves. Note the oil piston chamber at left. (SKF Industries.)
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this style coupling, large amounts of parallel misalignment are made possible by converting the angular misalignment capacity per mesh to parallel misalignment. Parallel misalignment capacity for one single-engagement coupling is virtually nonexistent, however, and these couplings must be used in pairs, as shown in Fig. 16.20, to handle parallel misalignment. Gear couplings must be lubricated for proper operation. Because of the high contact pressures obtained under misaligned conditions, only extreme-pressure (EP) greases should be used with gear couplings operating at maximum load. At high speeds (over 25 000 rpm), centrifugal effects separate the filler (soap) from the oil in most greases; the filler then collects between the teeth, preventing the oil from lubricating this highly loaded area. To overcome this problem, most highspeed gear couplings use a circulating oil system. The centrifugal effect still separates the fine particles from the oil, even in finely filtered systems. This sludge buildup necessitates cleaning of the teeth at regular intervals to prevent premature coupling failure. Gear couplings, while inherently balanced, being machined all over and selfcentering, may still require balancing to remove any residual unbalance due to bore runout. The magnitude F of this unbalanced or centrifugal force is F = me 2 (16.8) where m = mass of the coupling, e = eccentricity, and = angular velocity in radians per second. See also Chaps. 17 and 31. 16.3.5 Spring and Flexible Shaft
FIGURE 16.17 Cutaway of flange-type gear coupling. (Dodge Division, Reliance Electric.)
Flexible shafts are constructed from a casing and a core, which is a series of
Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
COUPLINGS 16.16
POWER TRANSMISSION
FIGURE 16.18 How double-engagement gear couplings accommodate angular, parallel, and axial misalignment.
multistranded layers of wire successively wrapped about a single central wire. Each wire layer is wound opposite to and at right angles to the layer beneath it to transmit maximum power and retain the greater flexibility. The casing protects the rotating core from dust and moisture, but does not rotate itself. It is also reinforced to support the core and prevent helixing under torque load. Helixing is the tendency for a rope, or wire, to bend back on itself when subjected to torsional stress (Fig. 16.21). The casing also provides a cavity for grease to lubricate the rotating core. The core is attached to the hub on either end and then connected to the equipment. The power transmission capacity of flexible shafting is limited only by the core construction, minimum radius of curvature of the shafting, and maximum unsupported length. Flexible shafts are commercially available with ratings up to 1500 pound-inches (lb in) at 440 r/min. Such a shaft is 11 2 in [38 millimeters (mm)] in diameter and has a minimum operating radius R of 24 in (600 mm). In Fig. 16.22, let R be the required
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