Rokee® Customized Hight Precision Universal Coupling for Customers, Rokee® is a well-known high-quality supplier of couplings and technical services in China.
As a key component in mechanical transmission systems, universal couplings play an irreplaceable role in solving the problem of two shaft non concentric transmission. High precision universal couplings have become core transmission components in fields such as aerospace, precision machine tools, and high-end equipment manufacturing due to their excellent deviation compensation capability and transmission accuracy.
High precision universal coupling is a mechanical device that can achieve continuous rotation and precise transmission of torque and motion in the presence of an axis angle between two shafts. Compared with ordinary universal couplings, high-precision universal couplings have significantly improved transmission accuracy, stability, and service life, and can meet the strict requirements of modern industry for precision transmission.
The core feature of high-precision universal couplings is their excellent angle compensation ability. The compensation range for the angle between the two axes of universal couplings of different structural types is usually between 5 ° and 45 °. This type of coupling has a compact structure and high transmission efficiency. It can compensate for axial, radial, and angular deviations while maintaining extremely high transmission accuracy. The instantaneous speed error can be controlled within 0.1%.
According to different application scenarios, high-precision universal couplings can be divided into two categories: measurement stage and power stage. Measurement grade universal couplings are mainly used for connecting precision measuring instruments and sensors, transmitting small torque but requiring extremely high transmission accuracy; Power grade universal couplings are used in high-precision machine tools, aerospace equipment, and other applications that require simultaneous transmission of large torque and high precision.
In terms of material selection, high-precision universal couplings are usually made of high-strength alloy steel, aviation aluminum alloy, or special composite materials. Key components such as cross shafts and bearings are made of high-purity bearing steel and undergo special heat treatment processes, with a surface hardness of HRC58-62, ensuring long-term stable operation under high-speed heavy load conditions.
With the continuous improvement of transmission accuracy requirements in modern industry, high-precision universal couplings are developing towards higher speeds, greater torque, longer lifespan, and intelligent monitoring, becoming an indispensable core component in the field of high-end equipment manufacturing.
The structural design of high-precision universal coupling embodies the essence of precision mechanical engineering, which mainly consists of the following key components to form a precision fit system:
Cross shaft assembly: As the core component of high-precision universal coupling, the cross shaft is made of high-purity bearing steel (such as GCr15) through special heat treatment process, with a surface hardness of HRC60-64 and precision grinding processing, with a roundness error of no more than 0.001mm. High precision needle roller bearings are installed on the four journals of the cross shaft, and special cage design and ceramic needle rollers are used inside the bearings to greatly reduce the friction coefficient and improve the speed capability.
Fork head component: It is usually forged from high-strength alloy steel (such as 42CrMo) and precision machined. The bearing hole that matches with the cross shaft has a machining accuracy of IT5 level and a surface roughness of Ra0.2. The fork heads of high-precision models will undergo dynamic balancing processing, with a balancing level of G2.5 or even higher, ensuring stability during high-speed operation.
Spline expansion sleeve: a high-precision spline pair used to compensate for axial displacement. It adopts an involute tooth design, with the tooth surface polished and the clearance controlled within the range of 0.02-0.05mm. Some high-end products adopt a double helix spline design, which can simultaneously compensate for axial displacement and angular deviation.
Lubrication system: High precision universal couplings are usually equipped with centralized lubrication systems or long-term lubrication units. The lubricant used is fully synthetic high-speed grease, and some extreme working conditions use solid lubrication or oil mist lubrication to ensure long-term maintenance free operation.
Central monitoring unit: Some intelligent high-precision universal couplings are integrated with vibration sensors and temperature monitoring modules, which can monitor the operation status of the couplings in real time and achieve predictive maintenance.
The working principle of high-precision universal coupling is based on the perfect combination of spatial linkage mechanism and precision bearing technology, and its transmission process can be divided into three key stages:
Torque input stage: The rotational motion of the active shaft is transmitted to one side fork through a flange or spline, driving the cross shaft to rotate around its axis. The transmission accuracy in this stage mainly depends on the connection accuracy between the fork and the shaft. High precision models usually use taper fit or hydraulic expansion sleeve connection to ensure seamless transmission.
Angle conversion stage: The cross axis transfers the rotational motion to the other fork, achieving compensation for the angle deviation between the two axes. The transmission accuracy at this stage depends on the fit accuracy between the cross shaft and the bearing. High precision design will control the radial clearance of the bearing within 0.005mm and use a pre tightening structure to eliminate the clearance.
Torque output stage: The driven fork transmits motion to the driven shaft, completing the entire transmission process. To maintain high transmission accuracy, the arrangement of the dual universal coupling should follow the principle of consistent phase angle, that is, the fork heads at both ends are in the same plane to eliminate speed fluctuations.
Over the years, with excellent quality, we have been continuously providing many coupling products of various categories and uses complying with multiple standards and a full range of services, from the product selection to final installation and operation, for the industry fields of ferrous metallurgy, nuclear power, gas turbine, wind power, ropeway construction, lifting transportation, general equipment, etc. We strictly comply with quality system requirements and implement the whole process control to become a reliable and trustworthy partner of customers.
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