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Applications

Manufacturers use flexible shaft couplings in rotary equipment and machinery to connect shafts and transfer torque. This equipment includes driveshafts, line shafts, power transmissions, wheels, and more. These couplings also serve to isolate propeller pulses, dampen driveline vibrations, and reduce gear chatter.

Flexible shaft couplings are commonly found in boats, hydraulic pumps, wind turbines, tube shafts, automobiles, paper-making machines, printing machines, compressors, roll formers, and blowers.

Industries that rely on flexible shaft couplings include aerospace, automotive, construction, metal processing, mining, mineral processing, power generation, quarrying, and cement.

Flexible Shaft Coupling – Lovejoy, Inc.

History

The earliest use of flexible couplings dates back to around 300 BC by the Greeks, followed by the Chinese around 25 AD.

In the 1500s, Jerome Cardan invented the modern flexible coupling, which included a cross, two yokes, and four bearings. Later, in 1650, Robert Hooke devised the first practical application of the Cardan joint (Cardan shaft), often referred to as the Hooke joint, using it to aid rotating shafts in clock drives.

In 1821, Irishman John Oldham invented the Oldham coupler to address issues with paddle steamers, a design still in use today.

Significant advancements in flexible couplings occurred in 1886 when F.M. Roots proposed modifying a rigid coupling to create a more flexible one, preventing shaft failure. This theory underpins modern diaphragm couplings.

During the early 1900s, especially the 1920s, flexible couplings saw rapid adoption, with manufacturers emerging across the United States. This surge was driven by the burgeoning auto industry, which relied heavily on couplings. One crucial type for early automobiles was the metallic disc coupling. However, until the 1940s, these couplings were only effective for low-speed, low-torque, and low-misalignment applications.

Between 1930 and 1945, engineers developed various coupling types still in use today, such as jaw couplings, disc couplings, gear couplings, chain couplings, slider block couplings, and grid couplings. The late 1940s and 1950s saw significant improvements in coupling misalignment allowance and power, responding to new equipment like rotary machinery that required lighter, faster, and more flexible couplings.

Today, manufacturers continually innovate couplings to keep pace with evolving technology. While the fundamental concept remains unchanged, modern couplings come in materials, shapes, and sizes previously unimaginable, benefiting from CNC technology for greater precision and quality.

Design

Production Processes

The construction of flexible shaft couplings involves several methods, including electroforming, chemical deposition, mechanical forming, and welding.

Electroforming: This process involves layering metal onto a mandrel until the coupling achieves the desired thickness.

Chemical Deposition: Similar to electroforming, this method deposits materials through electrodeposition.

Roll-forming: A common continuous shaping process where metal is shaped using contoured forming rolls.

Extrusion: In mechanical forming, this technique involves pushing metal stock through a shaped die to match the die’s shape.

Welding: This method involves welding a series of rings or washers from both the outside and inside to ensure maximum strength.

Materials

Manufacturers typically use aluminum or stainless steel for flexible couplings. Aluminum couplings are cost-effective and lightweight, while stainless steel couplings provide superior strength, enhanced corrosion resistance, and improved torque capacity.

Types

Flexible shaft couplings are categorized into three primary types based on their flexibility and intended use: mechanical, elastomeric, and metallic membrane. Additionally, various manufacturers produce custom or specialized shaft couplings for specific applications.

Mechanical Flexible Couplings

Mechanical flexible couplings consist of multiple fitted parts that slide or roll against each other. Despite requiring periodic lubrication and maintenance, they are a worthwhile investment due to their high torsional rigidity and ability to handle significant angular misalignment.

Jaw couplings, also known as spider couplings, comprise two metal hubs connected by an elastomeric element called the spider. They are ideal for applications requiring vibration reduction and offer resistance to moisture, dirt, sand, grease, and oil. They do not need lubrication. However, they struggle with misalignment.

Oldham couplings are compact and provide flexibility for non-linearly aligned shafts. They feature three discs: one connected to the input shaft, one to the output shaft, and one linking the two via perpendicular tongue and groove sets. All three discs rotate at the same rpm.

Servo couplings are designed to transfer torque with low inertia, no backlash, and high torsional stiffness.

Uniflex couplings are one-piece couplings that handle high shaft misalignment, high temperatures, and space constraints. They are used in various industries, including textiles, robotics, printing, conveying, packaging, and agriculture.

Encoder couplings connect encoder shafts with rotating shafts.

Spacer couplings are installed between a pump shaft coupling hub and a motor shaft coupling hub, creating space for seal removal during maintenance without causing damage.

Elastomeric Flexible Couplings

Elastomeric flexible couplings transmit torque between metallic hubs using materials like rubber or plastic. They are lightweight, offer high vibration dampening, are inexpensive, tolerate high degrees of misalignment, provide resilience and shock absorption, and do not require lubrication.

Bellows couplings connect shafts needing more flexibility or non-linear alignment.

Bush pin flange couplings are elastic couplings for slightly misaligned shafts, featuring a rubber bushing that absorbs vibration and shock.

Metallic Membrane Flexible Couplings

Metallic membrane couplings are relatively expensive and typically do not permit offset misalignment. However, they are low maintenance and do not require lubrication, offering flexibility through bendable membranes.

Fluid couplings, though not necessarily flexible couplings themselves, work alongside flexible couplings by transferring energy through oil via a pump. They are often used as motor couplings, providing low-load starting, shock absorption, and overload protection. They gain misalignment tolerance when paired with flexible couplings.

Universal joints, or universal couplings, provide a full range of motion by allowing the shaft to rotate and bend while delivering torque to the wheels. The central hub of the universal joint connects the shaft to the third element, allowing more bending than a flexible shaft coupling.

Gear couplings transfer rotary motion at a 90-degree angle. Designed like a sprocket, they connect shafts while providing torque. For equipment designed with more than 5 degrees of misalignment, manufacturers use universal joints or gear couplings
Misalignment Management

One of the key benefits of flexible shaft couplings is their ability to handle various types of misalignment effectively.

Misalignment happens when the shaft’s rotational axis deviates from its intended path, which can be caused by movement, vibrations, or impacts during operation. There are several types of misalignment: Parallel misalignment occurs when the shafts’ rotational axes are parallel but not aligned; Angular misalignment occurs when the shafts intersect at an angle; and Skewed misalignment happens when both axial and angular misalignment are present simultaneously.

Axial Displacement Accommodation

In addition to managing misalignment, flexible shaft couplings serve other crucial functions in mechanical systems. Axial displacement, or end float, refers to the movement of shafts along their axes, either moving towards or away from each other. Flexible shaft couplings help accommodate this displacement by absorbing shocks and dampening vibrations, ensuring smoother operation and prolonging equipment life.

Accessories

Examples of Flexible Shaft Coupling Accessories

To maintain and optimize the performance of flexible shaft couplings, you might need various accessories, including coupling grease/lubricant, fitting kits, encoder attachments, keyway connections, nuts and bolts, repair kits, and more.

• Coupling Grease/Lubricant: Specifically designed for shaft couplings, coupling grease or lubricant reduces friction and wear between coupling components like hubs and inserts. Proper lubrication ensures smooth operation, lowers heat generation, and extends the coupling’s lifespan. Regular reapplication is necessary for optimal performance.
• Fitting Kits: These kits contain tools and components essential for the correct installation and maintenance of shaft couplings. They often include torque wrenches, alignment tools, shims, and other hardware to ensure precise alignment and secure attachment. Fitting kits are crucial for proper installation and maintenance throughout the coupling’s operational life.
• Coupling Encoder Attachments: Encoder attachments integrate encoders with shaft couplings to provide feedback on rotational speed and shaft position. This enables accurate monitoring and control, which is vital for applications requiring precise operation, such as robotics, CNC machines, and automated systems.
• Keyway Connections: Keyways are slots machined into shafts and coupling hubs where a key is inserted to create a strong, rigid connection. This setup transmits higher torques without slipping and is commonly used in heavy-duty applications like large industrial machines.
• Nuts and Bolts: Standard fasteners that secure coupling components together. Using high-quality nuts and bolts prevents loosening and disengagement during operation, reducing the risk of coupling failure and machinery damage.
• Repair Kits: These kits include replacement parts for components that commonly wear out, such as inserts, bushings, and bolts. Keeping a repair kit handy allows for quick maintenance and part replacement, reducing downtime and extending the coupling’s lifespan.

To choose the right accessories, consider factors like the application’s operating conditions, required torque and speed, and the coupling’s design and specifications. Manufacturers often provide guidelines for selecting appropriate accessories based on their products.

Accessories can be sourced from authorized distributors, industrial supply stores, or directly from coupling manufacturers. Ensure that these accessories meet the coupling’s specifications and quality standards for proper function, safety, and reliability.

Regular maintenance, including proper lubrication and adherence to manufacturer guidelines, is essential for optimal coupling performance and longevity. Investing in high-quality accessories and diligent maintenance can significantly enhance the lifespan and performance of shaft couplings in various industrial and mechanical settings.

Standards

Shaft couplings play a crucial role across various industries, and adhering to international standards is essential for ensuring their safety, reliability, and consistent performance. Key ISO (International Organization for Standardization) standards for shaft couplings include ISO 14691, ISO 16021, ISO 13041, and ISO 6336. These standards address a range of factors such as terminology, dimensions, performance testing, and design guidelines for different coupling types, including rigid, flexible, and gear couplings.

Following these standards is vital for ensuring that couplings from different manufacturers and for various applications are compatible and interchangeable. Standardization promotes consistency in design, materials, and manufacturing processes, which enhances safety and simplifies maintenance. Adherence to ISO standards provides a common framework for engineers, manufacturers, and end-users, facilitating effective communication and understanding during the selection and use of couplings.

To identify the applicable standards for specific shaft coupling applications, individuals can consult ISO’s website or reach out to relevant national standards organizations. Coupling manufacturers also often provide information on the ISO standards their products meet. Seeking advice from experts or engineers in the field can further aid in understanding and selecting the right standards.

Using shaft couplings that do not meet the relevant ISO standards can lead to significant issues. Non-compliant couplings may underperform under designated loads, speeds, or environmental conditions, resulting in premature wear, failure, and potential damage to connected machinery. They may also lack essential safety features or undergo insufficient testing, increasing the risk of accidents, downtime, and costly repairs.

Conversely, shaft couplings that comply with ISO standards offer numerous advantages. They provide a high level of confidence in performance and reliability, having been rigorously tested to handle specified torque, misalignment, and environmental conditions. ISO-compliant couplings adhere to recognized design practices, ensuring proper fit and functionality with standard components and equipment. Additionally, compliant couplings facilitate easier maintenance due to the availability and interchangeability of spare parts.

In summary, adhering to ISO standards in shaft coupling design and manufacturing is crucial for ensuring safe, reliable, and consistent performance. Information about applicable standards can be accessed through ISO’s official resources or industry experts. Choosing couplings that meet these standards minimizes operational risks, damages, and maintenance costs, while providing enhanced reliability and the benefits of standardized design and performance.

Choosing the Right Manufacturer

To find the best flexible shaft couplings for your needs, partnering with an experienced coupling manufacturer is essential. To help you with this, we’ve compiled a list of reliable shaft coupling suppliers on this page. Before reaching out to them, we suggest jotting down your specifications and requirements. This will streamline the process of evaluating potential manufacturers and help you quickly identify the best matches. Additionally, having your list of specifications handy will make your discussions with the top three or four manufacturers more focused and productive.

An ideal manufacturer will not only provide high-quality products within your budget but also offer suitable delivery options. Keep in mind that some manufacturers cater to a wide range of applications, while others specialize in automotive components (such as flywheel couplings, torque limiters, driveshafts, and tire couplings) or specific industry equipment. The right choice will depend on the specifics of your application. With these considerations in mind, start your search, and good luck!