Shaft Couplings

Types, selection, installation & maintenance of couplings

Presented by Sandeep Gupta CSC Unit -2

Shaft coupling
Used to transmit power generally from a prime mover to a driven equipment

Basic functions of flexible couplings

1. Transmit power

2. Accommodate misalignment

3. Compensate for end movement

Types of couplings
Rigid couplings
Does not allow any misalignment between drive and driven equipment shaft centre lines

Flexible couplings
Allow a limited degree of misalignment by using one of the following types of flexible elements

-Mechanical element -Elastomeric element -Metallic element

Rigid coupling types

Used when
the equipment has virtually no misalignment and /or when equipment / coupling are capable of withstanding forces and moments produced due to misalignment Example : small inline vertical pumps where thrust bearing is only in electric motor

Types
Flanged Sleeve

Rigid Coupling Flange Type

Rigid Coupling Sleeve type

Gear Couplings
-Invented by Guston Fast
-Being manufactured since world War 1 -Mechanically flexible coupling -Uses external and internal involute profile gear teeth with 20 to 25 degree pressure angle -Transmits power with 1:1 gear ratio -Have largest torque to weight ration among all coupling types - A single set of coupling half ( hub + sleeve) can take up angular misalignment only. Hence these are normally used with two pairs of coupling halves.

Gear Coupling Construction

Main parts
Hubs with external gear teeth Sleeves with internal gear teeth Hub O rings Bolts and lock nuts Gasket between hub

Gear coupling tooth form

Have you ever noticed any difference in tooth form of a gear coupling and a normal spur gear ?

Straight vs Crowned tooth profile

Crowned (shaped) tooth

Straight ( conventional )tooth

Gear coupling- straight and crowned tooth form

Straight tooth profile

Crowned tooth profile A : Flank Crowning B : Tip or root crowning C : Chamfer crowning

Gear coupling Why straight teeth is not preferred ?

Straight teeth : Gives rise to loading in very limited contact area at the end of meshing teeth in case of angular misalignment

Crowned teeth : Increases loading contact area on meshing teeth in case of angular misalignment

Gear coupling Teeth in mesh in misaligned coupling

Gear couplings tooth form types

Sleeve :
internal teeth on sleeve are always straight sided teeth. Most of backlash required for misalignment is provided in sleeve

Hub :

Straight teeth result into excessive end loading on tooth in case of angularly misaligned couplings. Hence it can normally take up to 1/4 of angular misalignment with required backlash. Hence external teeth on hub are normally crowned to increase contact area between meshed teeth during operation in misaligned conditions.

Gear Coupling Types of tooth crowning

These teeth are crowned hobbed or shaped with a cutter on a cam. This produces a pitch diameter that is on a curve These teeth are crowned hobbed or shaped with a cutter on a cam. This produces a pitch diameter that is on a curve Crowned tooth with pitch diameter on a straight line

Crowned tooth with pitch diameter on a curve

These are also crowned flank but radii of curvature increasing from center to end
Variable Crowned tooth

Gear Couplings Lubricant seal types

Seals are required to retain the lubricant in coupling internal space Four types of seals are used

Labyrinth Seal

High misalignment lip seal

O ring

Molded rubber

Gear Coupling Coupling half types

Left side :

Flexible Flexible Gear Coupling Both coupling halves are flexible can take up angular as well as offset misalignment Flexible Rigid Gear Coupling Only one coupling half is flexible, other is rigid Can take up only angular misalignment

Right side :

Gear Coupling - Advantages

Torque capacity for a given diameter is higher than any other type of coupling Saving in weight and space Can handle high temperature as it is made entirely of metallic parts except O rings which could be replaced with Viton O rings or metallic seals High torsional stiffness Good inherent balance

Grid Coupling
Invented by James Bibby of London , England in 1920 Available in vertical and horizontal split covers design Have Torsional flexibility and prevents shock loads from transmitting through system

Helps in vibration dampening as shock energy is stored in form of deformation energy in grid

Grid coupling - construction

Consists of
Two identical hubs with radially extending hub teeth on the gap end Slots between the hub may be either parallel sided or tapered and contain an axial curvature on their faces Grid A flat rectangular or trapezoidal X section serpentine spring steel member

Covers to contain grid and lubricant

O rings to prevent grease leakage

Grid Coupling Non linear torsional stiffness Gets stiffer with increasing load

Light load : The grid bears near the outer edges of the hub teeth. Torsional stiffness is lower

Normal load : distance between contact points decreases. Torsional Stiffness also increases.

Shock load : The grid bears fully on the hub teeth and transmits full load directly. Torsional stiffness is minimum

Grid Coupling - Misalignment

Parallel misalignment get accommodated by Tipping and sliding of grid in hub slots Deflection of grid

Angular misalignment get accommodated by sliding of grid in hub slots

Axial end float is accommodated by designing axial clearances between the hub , cover and grid loop ends

Grid coupling types

Horizontal split : This design permits easy access to the grid member while requiring the least amount of axial space

Vertical split : This design used for high speed but requires greater axial space for grid access and cover assembly

High speed: This design is vertically split one with single cover bolted to a flanged hub. This gives better coupling balance as the cover is located concentrically and cover would not spin during rapid start and stop

Disc Coupling
Invented by Millward T. Thomas in 1914 No relative motion between coupling parts hence no lubrication required. Practically maintenance free coupling All metal coupling without any rubber parts hence suitable for high temperature applications No backlash, high torsional stiffness. Hence suitable for servo positioning systems No wearable parts infinite life if selected properly Produce lower reactionary force than gear coupling when in misalignment

Disc Coupling Construction & torque transmission

Consists of two flanged hubs, a center spacer and two disc packs Each disc pack is connected to a hub and the centre spacer by alternate bolts. Disc packs multi laminate type made of many thin disc elements clamped together (thickness 5 thou to 25 thou)

Torque is transmitted from the hub to the centre spacer thru alternate legs of the disc pack
Alternate legs are in tension while other legs are in compression . Torque is mainly transmitted by legs in tension. Legs in compression contribute very little. Capacity for angular misalignment is dependent on free span between bolts. Flexibility varies as cube of the span

Disc Coupling Disc outside diameter profile

CIRCULAR Easiest to produce Acts as curved beam, hence high compression stresses are set up on outer fibres STRIAGHT SIDES Stresses in legs are simple tensile stress
COST PERFORMANCE Increases increases

SCALLOPED Inoperative outer portion of leg is removed. More flexible disc pack when subjected to both axial and angular deflections. LINKS Used for very large couplings Permits assembly by wrapping the links around the hubs

Disc Coupling No. of bolt holes

Four Bolts Angular misalignment capacity = 1

More no. of bolt holes are required for higher torques More no. of bolts in same diameter reduces the free span between bolt holes and hence also reduces flexibility and angular misalignment

Six Bolts Angular misalignment capacity = 1

Eight Bolts Angular misalignment capacity = 1.5

Disc Coupling some common failures

Symptom: Disc broken through the bolt hole indicates loose coupling bolts. Remedy: Replace disc pack and tighten lock nuts to specified torque ratings.. Symptom: Disc broken adjacent to washer face usually indicates excessive shaft mis lignment. This type of disc failure usually starts with outer disc and progresses through disc pack. Remedy : Replace both disc packs and realign machine shafts. Symptom: Disc broken adjacent to washer face with fretting corrosion present in the area of crack usually indicates excessive shaft misalignment during operation. Also iron oxide most likely to be evident on outside of disc. Sometimes associated with a coupling that has been in service for several years and /or operating in corrosive atmosphere. Remedy : Replace both disc packs and realign machine shafts.

Disc Coupling some common failure

Symptom :Disc pack has bulge near the center or is bowed toward one flange in alternate chord positions, or the bolts are bent. Remaining disc pack chordal sections will very straight and tight Reason : Large torque overload above the peak overload capacity of the coupling Remedy: Check the coupling selection. Apply the proper size and style for characteristics present.

Symptom : Disc pack is wavy and the dimension between flange faces is smaller than indicated in assembly drawing Reason : Coupling has been installed in a compressed condition or equipment has shifted axially during operation. Remedy: In case of sleeve bearing motor , make sure that the operating centreline of the motor rotor is positively positioned. Relieve disc pack compression during operation

Elastomeric shear couplings Tyre coupling

Tyre coupling misalignment motion

Tyre coupling ability to take up misalignment is similar to three bar linkage

Parameters for Coupling Selection

Power transmitted in kW Operating speed

Shaft coupling Interface connection information

Torques Angular misalignment Offset misalignment Axial travel Ambient temperature Critical frequencies for potential excitation (torsional, axial , lateral) Limitation on coupling generated forces (Axial, moments, unbalance) Any other unusual condition coupling characteristics - weight , torsional stiffness etc

Coupling Type Selection

Application
Variable, high torque machine trains operating at moderate speeds Vertical pump shafting Key and keyways not appropriate ( e.g. brass shaft)

Coupling type
Metallic grid coupling Flanged rigid coupling, split rigid, or clamp coupling Rigid compression couplings

Transmission of proportionately high torque at low Chain couplings (mechanical speeds flexing)
Transmission of proportionately high torque at low speeds Allowance for axial movement and reduction of heat and axial movement Light or medium duty applications running at moderate speeds Gear coupling ( Mechanical flexing) Laminated disk ring coupling (material flexing) Elastomeric coupling (Material flexing)

Coupling Type Selection

General purpose couplings functional capabilities- selection

Special purpose couplings functional capabilities - selection

General purpose couplings characteristics - selection

Special purpose couplings characteristics- selection

Coupling requirements as per standard API 610 (centrifugal pumps standard for oil, natural gas and chemical industries)
Clause 6.2 of API 610 standard specifies requirement of Couplings and guards

Clause 6.2.1 : coupling and guards between drivers and driven equipment shall be supplied and mounted by the manufacturer of the pump.
Clause 6.2.2 : All-metal flexible element, spacer-type couplings in accordance with AGMA 9000 Class 9 shall be provided.
a) flexible elements shall be of corrosion-resistant material; b) couplings shall be designed to retain the spacer if a flexible element ruptures; c) coupling hubs shall be steel; d) the spacer nominal length shall be at least 125mm (5in) and shall permit removal of the coupling, bearings, seal, and rotor, as applicable, without disturbing the driver or the suction and discharge piping; e) couplings operating at speeds in excess of 3 800 r/min shall meet the requirements of IS0 10441 or AP1671 for component balancing and assembly balance check.

Clause 6.2.3 : If specified, couplings shall be balanced to IS0 1940-1 grade G6.3. Clause 6.2.4 : If specified, couplings shall meet the requirements of IS0 14691, IS0 10441 or API 671.

Coupling requirements as per standard API 610 (Centrifugal pumps standard for oil, natural gas and chemical industries)
Clause 6.2.5 : Information on shafts, keyway dimensions (if any), and shaft end movements due to end play and thermal effects shall be furnished to the vendor supplying the coupling. Clause 6.2.6 : Unless a proprietary clamping device is specified (see 6.2.11), flexible couplings shall be keyed to the shaft. Keys, keyways, and fits shall conform to AGMA 9002, Commercial Class Clause 6.2.7 : Couplings and coupling to shaft junctures shall be rated for at least the maximum driver power, including the service factor. Clause 6.2.8 : For shaft diameters greater than 60 mm (2.5 in) and if it is necessary to remove the coupling hub to service the mechanical seal, the hub shall be mounted with a taper fit. The coupling fit taper for keyed couplings shall be 1-in-I6 [60mm/m diametral]. Appropriate assembly and maintenance procedures should be used to assure that taper fit couplings have an interference fit Coupling hubs with cylindrical bores may be supplied with slip fits to the shaft and set screws that bear on the key. Slip fits on cylindrical bores allow adjustment of the coupling axial position in the field without application of heat. Clause 6.2.9 : Coupling hubs designed for interference fits to the shaft shall be furnished with tapped puller holes at least 1 O mm. (0.38 in) in size to aid in removal

Coupling requirements as per standard API 610 (Centrifugal pumps standard for oil, natural gas and chemical industries)
Clause 6.2.11 : If specified, couplings shall be fitted with a proprietary clamping device. Clause 6.2.12 : Provision shall be made for the attachment of shaft alignment equipment without the need to remove the spacer or dismantle the coupling in any way. One way of achieving this is to provide at least 25 mm (1 in) of bare shaft between the coupling hub and the bearing housing where alignment brackets may be located. Clause 6.2.13 : If the vendor is not required to mount the driver, the fully machined half coupling shall be delivered to the driver manufacturers plant or any other designated location, together with the necessary instructions for mounting the half coupling on the driver shaft. Clause 6.2.14 : Each coupling shall have a coupling guard which is removable without disturbing the coupled elements and shall meet the following requirements: a) Coupling guards shall enclose the coupling and the shafts to prevent personnel from contacting moving parts during operation of equipment train. Allowable access dimensions shall comply with specified standards, such as IS0 14120, EN 953 or ASME B15.1. b) Guards shall be constructed with sufficient rigidity to withstand a 900N (200 Ibf) static point load in any direction without the guard contacting moving parts. c) Guards shall be fabricated from solid sheet or plate with no openings. Guards fabricated from expanded metalor perforated sheets may be used if the size of the openings does not exceed 1 O mm (0,375 in). Guards shall be constructed of steel, brass or non-metallic (polymer) materials. Guards of woven wire shall not be used. If specified, non-sparking guards of agreed material shall be supplied

Coupling Balancing
Couplings can be brought into balance by four basic methods Tighter manufacturing tolerances Component balancing Assembly balancing Field balancing on the equipment Tighter manufacturing tolerances Clearance fit and large tolerances gives rise to potential unbalance Amount of potential unbalance could be reduced by tightening fits and tolerances

Coupling balance potential unbalance calculation for clearance fit

A typical clearance fit used in coupling is H7/g6 If shaft basic size is 50 mm then Size of shaft would be 50 mm

Selection of Shaft Coupling fits

Selection of a clearance or interference fit is influenced by several factors such as
Ease of assembly System sensitivity to unbalance Available equipment Forces generated during operation of coupling

Clearance fits : Ease of assembly and disassembly Hubs secured on shaft by tightening of set screws. Hence clearance fits work well as long as the setscrew can generate enough friction force to overcome the forces generated by coupling. (eg. Due to deformation of disc, elastomeric element and axial thrust in gear couplings) Give rise to potential unbalance due to clearances (as a set screw on a clearance fit hub is tightened, the hub is pushed to one side. Shift in hub position sets an unbalance.) Hence not suitable for high speed application more than 3000 rpm. Due to clearance fits, hub may rock on shaft and result in fretting of shaft hence not used on shafts size more than 4 and high power machines more than 150 HP. Preferred for vertical VS4 and VS5 type pumps where axial positioning and securing of coupling hub(s) is required

Selection of Shaft Coupling fits

Interference fits : Preferred where positive axial location of the hubs on shafts is required. Preserve the inherent balance quality of the coupling. Hence suitable for high speed application more than 3000 rpm. No rocking of hub on shaft and hence used high power machines of more than 150 HP. Interference fits are not suitable for hubs made of brittle materials. Interference fit stresses can cause the hubs to crack. Coupling hubs with interference fits are generally mounted to the shaft by heating the hubs. The best methods for heating the hubs are with an oven, hot plate, induction heater or a hot oil bath.

Coupling assembly balance

Coupling assembly balance

Shaft -Coupling hub preferred tolerances and resulting fits

IEC ELECTRIC MOTOR SHAFT SIZE TOLERANCES

Mechanical tolerance ISO tolerance to DIN 748, DIN 7160, DIN 42948 . up to 28 mm Diameter shaft end (dimension D ) 38 to 50 mm more than 50 mm up to 230 mm more than 230 mm j6 k6 m6 j6 h6

Mechanical tolerance
ISO tolerance to DIN 748, DIN 7160, DIN 42948 .

Register Diameter (dimension N )

Shaft -Coupling hub preferred tolerances and resulting fits

Shaft -Coupling hub preferred tolerances and resulting fits

Shaft -Coupling hub preferred tolerances and resulting fits

Shaft Coupling tolerances recommended by Flender

Key to Hub keyway fit

Two classes of fits are used Normal js9 (preferred) Close P9 ( hand fitted)