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The Coupling Handbook - Part
II
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First Steps in Coupling Selection - Types,
Considerations, and Charts
Selecting the right coupling is a complex task because
operating conditions can vary widely among applications.
Primary factors that will affect the type and size of coupling
used for an application include, but are not limited to:
horsepower, torque, speed (RPM), shaft sizes, environment
conditions, type of prime mover, load characteristics of the
driven equipment, space limitations and maintenance and
installation requirements. Secondary but possible essential
factors can include starts/stops and reversing requirements,
shaft fits, probable misalignment conditions, axial movement,
balancing requirements or conditions peculiar to certain
industries.
Because all couplings have a broad band of speed, torque,
and shaft size capabilities, those criteria are not the best
place to start. First, determine what attributes beyond those
basic criteria will be required for your application. If none
stand out then simply choose the lowest cost that fits those
basics. Almost always, though, there will be other
considerations that will narrow your alternatives down to
certain types of couplings.
As we review those other considerations that guide coupling
selection, we will omit rigid types and focus on flexible
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couplings.
A. Types of Flexible Couplings
Many types of flexible couplings exist because they all serve
different purposes. All types, however, fall into one of two
broad categories, Elastomeric and Metallic. The full range of
coupling types in both categories, and the special functions
of each, will be discussed thoroughly in later chapters. The
key advantages and limitations of both categories are briefly
contrasted here to demonstrate how they can influence
coupling selection.
1. Elastomeric
Couplings in this category include all designs that use a
non-metallic element within the coupling, through which the
power is transmitted. The element is to some degree
resilient (rubber or plastic). Elastomeric couplings can be
further classified as types with elastomers in compression or
shear. Some may have an elastomer that is in combined
compression and shear, or even in tension, but for
simplification they are classified as compression or shear,
depending on which is the principle load on the elastomer.
Compression types include jaw, donut, and pin & bushing,
while shear types include tire, sleeve, and molded elements.
There are two basic failure modes for elastomeric couplings.
They can break down due to fatigue from cyclic loading
when hysteresis (internal heat buildup in the elastomer)
exceeds its limits. That can occur from either misalignment
or torque beyond its capacity. They also can break down
from environmental factors such as high ambient
temperatures, ultraviolet light or chemical contamination.
Also keep in mind that all elastomers have a limited shelf life
and would require replacement at some point even if these
failure conditions were not present.
Advantages of Elastomeric Type Couplings
Torsionally soft
No lubrication or maintenance
Good vibration damping and shock absorbing qualities
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Field replaceable elastomers
Usually less expensive than metallic couplings that have
the same bore capacity
Lower reactionary loads on bearings
More misalignment allowable than most metallic types
Limitations of Elastomeric Type Couplings
Sensitive to chemicals and high temperatures
Usually not torsionally stiff enough for positive
displacement
Larger in outside diameter than metallic coupling with
same torque capacity (i.e. lower power density)
Difficult to balance as an assembly
Some types do not have good overload torque capacity
2. Metallic
This type has no elastomeric element to transmit the torque.
Their flexibility is gained through either loose fitting parts
which roll or slide against one another (gear, grid, chain) -
sometimes referred to as "mechanical flexing"-- or through
flexing/bending of a membrane (disc, flex link, diaphragm,
beam, bellows).
Those with moving parts generally are less expensive, but
need to be lubricated and maintained. Their primary cause
of failure is wear, so overloads generally shorten their life
through increased wear rather than sudden failure.
Membrane types generally are more expensive, need no
lubrication and little maintenance, but their primary cause of
failure is fatigue, so they can fail quickly in a short cycle
fatigue if overloaded. If kept within their load ratings, they
can be very long-lived, perhaps outlasting their connected
equipment.
Advantages of Metallic Type Couplings
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Torsionally stiff
Good high temperature capability
Good chemical resistance with proper materials selection
High torque in a small package (i.e. high power density)
High speed and large shaft capability
Available in stainless steel
Zero backlash in many types
Relatively low cost per unit of torque transmitted
Limitations of Metallic Type Couplings
Fatigue or wear plays a major role in failure
May need lubrication
Often many parts to assemble
Most need very careful alignment
Usually cannot damp vibration or absorb shock.
High electrical conductivity, unless modified with insulators
B. Application Considerations
Sometimes selection of coupling type is guided by
application, falling into one of five categories; General-
Purpose Industrial, Specific-Purpose Industrial, High-Speed,
Motion Control and Torsional. In each of these application
categories there would be elastomeric, metallic membrane
flexing, and mechanical flexing types.
Once the coupling type is selected, there may be variations
to consider within that type. For example, gear couplings
offer a wide variety of configurations to combine coupling
functions with other power train requirements, such as shear
pin protection or braking. It is always a good idea to
understand as much as possible about the two pieces of
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equipment to be connected. Let the driven equipment and
the driver dictate the needs of the coupling. For example, is
there a shock load or a cyclic requirement that may lead to
an elastomeric coupling? If low speed and high torque are
involved, that means a gear coupling is likely best suited.
High-speed machinery will lead to a disc or diaphragm
coupling. Diesel drivers need the benefits of torsional
couplings for best results. If the equipment is susceptible to
peaks or transients, the application may want high service
factor or a detailed analysis of the coupling torque
capabilities. That brings us to the list of requirements that
will impact the coupling selection.
The charts below will help provide the path among all the
couplings for most types of rotating equipment. The charts
are organized into three sections. The first is a list of
"Information Required" for the best possible selection of a
coupling. It reflects the selection process used by the OEM
equipment designer, the engineer/contractor, the coupling
specifier, or the trouble-shooter. For other situations, short
cuts are sometimes taken towards the conservative side.
The second is a chart of "Coupling Evaluation
Characteristics" such as torque, bore and misalignment.
The third is the chart showing "Coupling Functional
Capabilities. They are the attributes of the various
couplings that go beyond the numerical information.
C. Coupling Evaluation Charts
Information Required
1. Horsepower
2. Operating speed
3. Hub to shaft connection
4. Torque
5. Angular misalignment
6. Offset misalignment
7. Axial travel
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8. Ambient temperature
9. Potential excitation or critical frequencies (Torsional, Axial,
Lateral)
10. Space limitations
11. Limitation on coupling generated forces (Axial, Moments,
Unbalance)
12. Any other unusual condition or requirements or coupling
characteristics.
The first seven items of the list above will allow a coupling
selection if a service factor is used. The risk of relying on
service factors is the possibility of ending up with an
oversized coupling or one that is missing an essential
feature. All the remaining information, where applicable,
allows the coupling to be fine-tuned for the application.
Some types of couplings designed to do a specific job will
have a further list of needed information. For example, a
slider coupling has to have the sliding distance and the
minimum and maximum BSE dimension.
Note: Information supplied should include all operating or
characteristic values of connected equipment for minimum,
normal, steady-state, transient, and peak levels, plus the
frequency of their occurrence.
Information Required for Cylindrical Bores
1. Size of bore including tolerance or size of shaft and
amount of clearance or interference required
2. Length
3. Taper shaft (Amount of taper, Position and size of o-ring
grooves if required, Size and location of oil distribution
grooves, Max. pressure available for mounting, Amount of
hub draw-up required, Hub OD requirements, Torque
capacity required)
4. Minimum strength of hub material or its hardness
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5. If keyways in shaft (How many, Size and tolerance, Radius
required in keyway, Location tolerance of keyway respective
to bore and other keyways)<
Types of Interface Information Required for Bolted
Joints
1. Diameter of bolt circle and true location
2. Number and size of bolt holes
3. Size, grade and types of bolts required
4. Thickness of web and flanges
5. Pilot dimensions
6. Other
Once past the charts that follow, one can go directly to the
manufacturers catalog, or can read on to learn more about
specific couplings and the other important coupling issues.
Chart 1: General Coupling Evaluation Factors
Chart 2: General Functional Capability Chart
Chart 3: Lovejoy Specific Preselection Guide
Go To Next Section - Part 3: Popular Elastomeric
Coupling Types - Compression Loaded, Shear Loaded,
Combination, and Torsional
Go Back To Handbook Index
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