Introduction
Power transmission couplings are used to connect two shafts that turn in the same
direction on the same centerline. There are three principle types of couplings; rigid,
flexible and special purpose.
Rigid couplings are used in applications where misalignment is not a factor,
where flexibility is not required and where the coupling is not required to absorb load
shocks or torque changes. Rigid couplings connect shafts using bolted flanges, keyed
sleeves or ribbed clamps bolted together over the shaft ends with keyways. Rigid
couplings are used primarily for vertical drive systems. Lubrication is not required, but
larger couplings, or those running at high speeds, may require balancing to reduce
vibration.
Flexible couplings also connect two rotating shafts, but are designed to dampen
vibration, absorb some shock loading and provide some axial movement or end float of
the shafts, as well as compensate for minor misalignment.
There are three fundamental categories of flexible couplings; mechanically
flexible, such as gear and chain couplings, material flexible, such as disc, spring,
diaphragm, elastomeric and bellows and combination, such as metallic grid couplings,
that provide a combination of mechanical and material flexibility.
Special purpose couplings include such devices as mechanically flexible U-
joints and constant velocity joints used for automobile applications, magnetic
couplings, such as magnet to magnet and eddy current couplings and fluid couplings,
such as liquid, silicone and shot filled types. Magnet and fluid couplings provide no
contact between drive and driven elements, offer low maintenance and both are capable
of absorbing shock loads.
1
A unique special purpose type, the Schmidt or offset coupling is designed to
handle large parallel shaft offsets of up to 18 inches and 1,000,000 in-lbs of torque. (SEE
FIGURE 1.)
2
FIGURE 2.
3
Generally speaking these coupling types require little maintenance other than
alignment and their service life is limited by the fatigue limit of the flexing
material itself. (SEE FIGURES 4. & 5.)
4
FIGURE 5. Typical flexible coupling with elastomeric material which might be
natural rubber, urethane or neoprene.
5
FIGURE 6. Grid coupling. (The serpentine spring has been removed so that it does
not interfere with the alignment procedure).
FIGURE 7. The wear areas of the grid coupling are the grooved slots and the
serpentine spring.
1
insufficient lubrication, harsh environmental or operating conditions and excessive
speeds or loads.
2
TABLE 1.
3
FIGURE 8. Some manufacturers like Falk, provide a coupling selector guide that
carries the service factor for various equipment types and provides corresponding
coupling recommendations.
4
FIGURE 9. Types of Misalignment
Process fluid and/or oil leaks at the drive, driven (or both) shafts,
5
High vibration conditions, usually at both machines,
Cracked or broken foundation, particularly at or near the foot bolts,
6
FIGURE 10. Gear coupling with spacer undergoing laser alignment. The
coupling connects an electric motor driving a hammer mill.
Fluid couplings are referred to as special purpose, however they are also rigid
and cannot accommodate misalignment. (SEE FIGURE 11.)
1
FIGURE 11. Fluid coupling undergoing a laser alignment procedure.
2
Again note the minimum and maximum readings. Each 0.016 inch difference
between the two readings for each inch the indicator point is located from the
centerline of the shaft indicates an angular misalignment of about one (1) degree.
Another issue that may affect alignment is end float or axial shaft movement.
There is a tendency for shafts to be pulled closer to their own machine as soon as
they are started. As shafts tend to separate at startup, axial end float tries to pull
the coupling apart and allowable end float should not exceed inch.
1. The lubrication factor. There are three flexible coupling types that require
lubrication. These are gear and chain mechanically flexible couplings and
combination mechanical and material flexible grid couplings. The lubricants
used for gear and grid couplings may include; ISO 460 compounded oils with
tackiness additives for low speeds and centrifugal G forces of up to 8000 or
ISO 100 rust and oxidation inhibited anti-wear oils for high speeds, centrifugal
G forces of over 8000 and low temperatures of -20C (-4F).
NLGI Grades 1 and 2 coupling greases containing high viscosity oil fortified
with rust and oxidation inhibitors, extreme pressure additives and tackiness
agents to prevent separation at high speeds and high centrifugal G forces, may
be recommended for gear, chain and grid type couplings.
G = 14.2 X 10 6 dN2
Where d = pitch diameter of the coupling in inches
And N = revolutions per minute.
3
Generally, oil or grease can be used at coupling speeds of 3600 to 6000 rpm. Oil
is recommended where coupling speeds exceed 6000 rpm.
Gear and grid style couplings incorporate seals or gaskets to contain the lubricant
and prevent the entry of foreign material. These units contain access plugs for re-
lubrication which must be properly torqued after re-lubrication to ensure that
centrifugal force does not loosen the plugs and cause a serious safety hazard.
The amount of lubricant used is also important. Gear couplings, if overfilled with
lubricant, may lockup and the coupling will no longer maintain its flexibility.
(Any increase in vibration of the coupling after re-lubrication suggests
excessive lubricant). If a coupling is disassembled for re-lubrication, ensure that
the two flange halves are marked for correct reassembly and be certain to use
specified coupling flange bolts properly torqued. Install new seals or gaskets if
the old seals and gaskets have any damage, nicks or are no longer pliable.
Before reassembly of grid type couplings, carefully inspect the serpentine spring
for damage, wear or fatigue cracks and inspect the grid grooves for excessive
wear or evidence of fatigue. On chain and gear type couplings, inspect the chain,
sprocket and gear teeth for looseness, wear and evidence of fatigue. (SEE FIGURE
12.)
4
FIGURE 12. Courtesy American Axle & Manufacturing. Coupling shows
failed serpentine spring and grease residue that had undergone oxidation.
The old lubricant removed from the coupling should also be inspected for metal
particles indicating wear and darkening in colour suggesting oxidation.
Finally, after re-lubrication and re-installation, ensure that safety guards or mesh
screens are reinstalled and secured.
5
In addition, solvents, caustic process fluids and water washing practices may be
harmful to some elastomeric couplings and disc, grid or gear couplings may be
required. Wherever high loads and speeds are required, disc and gear couplings
may be the best choice.
6
7
8
These troubleshooting guidelines are general in nature and cover only those very
common flexible couplings described in the guide. For uniquely designed or
9
special purpose couplings, contact the appropriate manufacturer for selection,
maintenance and troubleshooting recommendations.
Conclusion
References
10