A coupling is a mechanical device that connects similar or dissimilar shafts in machines to

transmit power and movement. It is usually a temporary connection and capable of removal
for service or replacement. A coupling may be rigid or flexible.

In most cases, a coupling does not change the direction of motion or angular velocity, unlike
gears. It cannot be connected or disconnected mid-operation, unlike clutches. Couplings can
only transfer torque over short distances, for longer distances chain drives and belt
drives are better alternatives. Couplings are often paired with lead screw assemblies to
connect the screw shaft in-line to a motor.

The coupling works by maintaining a strong but flexible connection at all times between two
shafts to transfer motion from one shaft to another. It does so at all values of loads and
misalignment without permitting any relative motion between the two shafts.

The Purpose of Couplings

A shaft coupling can perform multiple functions in a machine. The design may incorporate
more than one of these coupling features into the product’s function in advanced
applications.

Let us take a brief look at what these are:

 Power transmission

 Shock and vibration absorption

 Misalignment accommodation

 Heat flow interruption

 Overload protection

Power transmission

The primary purpose in most cases is power and torque transmission from a driving shaft to
a driven shaft — for example, a coupling connecting a motor to a pump or a compressor.

Absorb shock and vibration

A shaft coupling can smooth out any shocks or vibrations from the driving element to the
driven element. This feature reduces the wear on the components and increases the service
life of the setup.

Accommodate any misalignment

Misalignments between shafts can result from initial mounting errors or may develop over
time due to other reasons. Most couplings can accommodate some degree of misalignment
(axial, angular and parallel) between shafts.

Interrupt heat flow

A shaft coupling can also interrupt the flow of heat between the connected shafts. If the prime
mover tends to heat up during operation, the machinery on the drive side is protected from
being exposed to this heat.

Overload protection

Special couplings known as Overload Safety Mechanical Coupling are designed with the
intention of overload protection. On sensing an overload condition, these torque-limiting
couplings sever the connection between the two shafts. They either slip or disconnect to
protect sensitive machines.

Types of Couplings

Couplings come in a host of different shapes and sizes. Some of them work great for generic
applications, while some others are custom-designed for really specific scenarios.

To make an informed choice, it is important to be aware of the capabilities and differences

between the different types of couplings. This section presents information about the
following types of couplings and how they work:

 Rigid coupling

 Flexible coupling

 Sleeve or muff coupling

 Split muff coupling

 Flange coupling

 Gear coupling

 Universal joint (Hooke’s joint)

 Oldham coupling

 Diaphragm coupling

 Jaw coupling

 Beam coupling
  Fluid coupling

Rigid coupling

As the name suggests, a rigid coupling permits little to no relative movement between the
shafts. Engineers prefer rigid couplings when precise alignment is necessary.

Any shaft coupling that can restrict any undesired shaft movement is known as a rigid
coupling, and thus, it is an umbrella term that includes different specific couplings. Some
examples of this type of shaft coupling are sleeve, compression and flange coupling.

Once a rigid coupling is used to connect two equipment shafts, they act as a single shaft.
Rigid couplings find use in vertical applications, such as vertical pumps.

They are also used to transmit torque in high-torque applications such as large turbines.
They cannot employ flexible couplings, and hence, more and more turbines now use rigid
couplings between turbine cylinders. This arrangement ensures that the turbine shaft acts as
a continuous rotor.

Flexible coupling

Any shaft coupling that can permit some degree of relative motion between the constituent
shafts and provide vibration isolation is known as a flexible coupling. If shafts were aligned all
the time perfectly and the machines did not move or vibrate during operation, there would be
no need for a flexible coupling.

Unfortunately, this is not how machines operate in reality, and designers have to deal with all
the above issues in machine design. For example, CNC machining lathes have high
accuracy and speed requirements in order to perform high-speed processing operations.
Flexible couplings can improve performance and accuracy by reducing the vibration and
compensating for misalignment.

These couplings can reduce the amount of wear and tear on the machines by the flaws and
dynamics that are a part of almost every system. As an added bonus they’re generally rather
easy to install and have a long working life.

“Flexible coupling” is also an umbrella term and houses many specific couplings under its
name. These couplings form the majority of the types of couplings in use today. Some
popular examples of flexible couplings are gear coupling, universal joint and Oldham
coupling.

Sleeve or muff coupling

Sleeve coupling is the simplest example of a rigid style coupling. It consists of a cast-iron
sleeve (hollow cylinder) or muff. It has an internal diameter equal to the external diameter of
the shafts being connected. A gib head key is used to restrict the relative motion and prevent
slippage between the shafts and the sleeves.

Some sleeve couplings and shafts have threaded holes that match up on assembly to
prevent any axial movement of the shafts. The power transmission from one shaft to the
other occurs through the sleeve, the keyway and the key. This shaft coupling is used for light
to medium-duty torques.

The sleeve coupling has few moving parts, making it a sturdy choice as long as all the parts
are designed keeping in mind the expected torque values.

Split muff coupling

For easier assembly, the sleeve in a sleeve coupling can be divided into two parts. By doing
this, the technician no longer needs to move the connected shafts for assembly or
disassembly of a coupling.

This is what a split muff coupling or a compression coupling is. The two halves of the sleeve
are held in place using studs or bolts.

Similar to sleeve coupling, these couplings transmit power through the key. Split muff
couplings are used in heavy-duty applications.

Flange coupling

In flange couplings, a flange is slipped onto each of the shafts to be connected. The flanges
are secured to each other through studs or bolts and onto the shaft by a key. Using set
screws or a tapered key ensures that the flange hub will not slip backwards and expose the
shaft interfaces.

One of the flanges has a protruding ring on its face, while the other has an equivalent recess
to accommodate it. This type of construction helps the flanges (and, in turn, shafts) maintain
alignment without creating any undue stress on the shafts.

Flange coupling is used in medium to heavy-duty applications. They can create effective
seals between two tubes, and hence, in addition to power transmission, they are used in
pressurised fluid systems. Flange couplings are of three major types:

 Unprotected type flange coupling

 Protected type flange coupling

  Marine type flange coupling

Gear coupling

A gear coupling is very similar to a flange coupling. However, it is a flexible type of coupling
and can be used for non-collinear shafts. Gear couplings accommodate angular
misalignment of about 2 degrees and parallel misalignment of 0.25…0.5 mm.

The setup for gear couplings consists of two hubs (with external gear teeth), two flange
sleeves (with internal gear teeth), seals (O-rings and a gasket) and the furnished fasteners.

The power transmission between the two ends of the coupling occurs through the internal
and external gears in the gear coupling.

Gear couplings are capable of high torque transmission. As a result, they find use in heavy-
duty applications. They require periodic lubrication (grease) for optimum performance.

Universal joint (Hooke’s joint)

When two shafts aren’t parallel and intersect at a small angle, we use a universal joint. This
joint can accommodate small angular misalignment while providing high torque transmission
capacity.

The universal joint consists of a pair of hinges connected through a cross-shaft. The two
hinges are positioned at 90 degrees to each other. The cross-shaft maintains this orientation
and is also responsible for the power transfer. The universal joint is not a constant velocity
coupling, i.e., the driving and driven shafts rotate at different speeds.

They find use in a variety of different applications, hence the name. The most popular uses
of universal joints are in car gearboxes and differentials.

Oldham coupling

Oldham Coupling

Oldham coupling is a special shaft coupling used exclusively for lateral shaft misalignment.
When two shafts are parallel but not collinear, an Oldham coupling is most suitable.

The design consists of two flanges that slip onto the shaft and a middle part known as the
centre disc. The centre disc has a lug on each face. The two lugs are actually rectangular
projections that are perpendicular to each other and fit into the grooves cut out into the
flanges on each side.

The flanges are fixed to the shaft through keys. Thus, the power transmission takes place
from the driving shaft to the key to the flange to the centre disc and then through the second
flange to the driven shaft.

Oldham coupling is ideal for scenarios where there is a parallel offset between two shafts.
Such parallel misalignment can happen in cases where power transmission is needed
between shafts at different elevations. When the shafts are in motion, the centre disc goes
back and forth and adjusts for the lateral variation.

Diaphragm coupling

Diaphragm couplings are great all-rounder shaft couplings. They can accommodate parallel
misalignment as well as high angular and axial misalignment. They also have high torque
capabilities and can transmit torque at high speeds without the need for lubrication.

Diaphragm couplings are available in various styles and sizes. The structure consists of two
diaphragms with an intermediate member between them. The diaphragm is basically one or
more flexible plates or metallic membranes that connect the drive flanges on the shafts to the
intermediate member through bolts on both sides.

Diaphragm couplings were initially developed for helicopter drive shafts. But over the years,
they have found much use in other rotating equipment as well. They are most commonly
used in turbomachinery due to their high-speed function. Applications today include turbines,
compressors, generators, aircraft, etc.

Jaw coupling

Jaw coupling is a material flexing coupling. It finds use in general low power transmission
and motion control applications. It can accommodate any angular misalignment. Similar to
diaphragm couplings, jaw couplings do not need lubrication.

This coupling consists of two hubs with intermeshing jaws that fit into an elastomeric spider.
The spider is usually made of copper alloys, polyurethane, Hyrtel or NBR and is responsible
for torque transmission.

Due to the elastic nature of the spider, it is suitable for the transmission of shock loads. It can
also dampen reactionary forces and vibration pretty well.

Engineers use jaw couplings in applications such as compressors, blowers, mixers and
pumps.

Beam coupling

A beam coupling is a machined coupling that offers high flexibility in terms of parallel, axial
and angular misalignment. It is one of the best low-power transmission couplings.

A beam-style coupling has a cylindrical structure with helical cuts. The attributes of these
cuts, such as their lead and the number of starts, can be modified to provide misalignment
capabilities of varying degrees. In fact, engineers can make these changes without
sacrificing the structure’s integrity as it is made of a single piece. Thus, a second name for
beam coupling is helical coupling.

In essence, beam couplings are actually curved flexible beams. They are available in single-
beam and multi-beam versions. Multi-beam couplings can handle greater parallel
misalignment than single-beam couplings.

A beam coupling is more suitable for low-load applications as torsional windup can be a real
issue. Thus, it is used in servo motors and motion control in robotics.

Fluid coupling
Fluid Coupling Working Principle

A fluid coupling is a special type that uses hydraulic fluid to transmit torque from one shaft to
another.

The shaft coupling consists of an impeller connected to the driving shaft and a runner
connected to the driven shaft. The whole setup is fixed in a housing, also known as a shell.

When the driving shaft rotates, the impeller accelerates the fluid, which then comes into
contact with the runner blades. The fluid then transfers its mechanical energy to the runner
and exits the blades at a low velocity.

A fluid coupling is used in automobile transmission, marine propulsion, locomotive and some
industrial applications with constant cyclic loading.

Parameters for Choosing

Shaft couplings are an integral component of motion control and power transmission
systems. They provide incredible advantages and combat many assembly and service
environment issues when applied correctly.

To do this, designers must consider many factors to make the right choice. Being aware of
them helps reduce instances of coupling failure and improve system capabilities. These
factors are:

 Torque levels

 Alignment limits

 Rotational speeds

 Lubrication constraints

Torque levels

Most manufacturers use rated torque as a basis for classifying coupling. The value of torque
depends on whether a coupling is used for motion control or power transmission
applications. The former has lower torque and loads compared to the latter. Knowing the
expected torque levels in an application will narrow down the selection of the right coupling.

Alignment limits
Different applications have different alignment needs. Similarly, some shaft couplings can
only accommodate one type of misalignment, while others can handle multiple types.

Manufacturers also mention the misalignment limits for different types of misalignment for
every coupling. This consideration helps further narrow down the search and pair the right
coupling with the right machine.

Maximum rotational speed

Every coupling also has a maximum allowable RPM. This limit is also published with shaft
couplings. General-purpose couplings cannot be used as-is for high RPM applications. High
RPM couplings need static and dynamic balancing to ensure safe, smooth and noise-free
service.

Such balanced designs are created by precise machining and appropriate fastener
distribution. Using the expected RPM as a yardstick can help with the correct coupling
selection.

Lubrication constraints

Sometimes, service conditions may prevent frequent relubrication of shaft couplings that
need it. On the other hand, some shaft couplings are designed without the need for any
lubrication over their entire life.

If the torque requirements are low, modified versions of conventional couplings are also
available. These versions come with metal-on-metal lubrication or metal and plastic
combinations to eliminate lubrication altogether. Designers must make the right coupling
choice by evaluating the service conditions and application needs.
Mechanical power transmission refers to the transfer of mechanical energy (physical motion)
from one component to another in machines. Most machines need some form of mechanical
power transmission. Common examples include electric shavers, water pumps, turbines and
automobiles.

In most cases, the rotational movement of the prime mover is converted into the rotational
movement of the driven machinery. However, the speed, torque and direction may change.

Occasionally, they may convert rotational motion into translational motion (back and forth
movement) depending on the application’s functional requirements. Such change may be
carried out using linkages or other machine elements.

Types of Mechanical Power Transmission

Different machine elements can transmit power between shafts in machinery. The most
common mechanical power transmission methods in use in the engineering industry today
are:

 Shaft couplings

 Chain drives

 Gear drives

 Belt drives

 Power screws (lead screws)

Shaft couplings
Shaft couplings connect two shafts and transmit torque between them. The shafts may be in
line, intersecting but not parallel, or non-intersecting and non-parallel. To cater to the needs
of various applications and environments, many different types and sizes of couplings are
produced.

Broadly, there are two types of shaft couplings- rigid and flexible. Rigid couplings do not
permit relative motion between shafts, whereas flexible couplings do. Hence, flexible
couplings can handle some shaft misalignment.

Some couplings, such as the split muff couplings, can be fixed onto shafts without moving
them. In contrast, most others require shaft movement for installation/removal.

Advantages

 Shaft couplings are low-maintenance machine elements

 They can absorb shock and vibration

 They can handle radial and axial misalignment

 They provide heat isolation

  Maintenance-free and permanently lubricated designs are available

Disadvantages

 Shaft couplings cannot be used for non-intersecting parallel shafts

 Rigid couplings may damage the shaft if misalignment creeps in

 Backlash may develop over the service life, putting the couplings, bearings and drive
components under additional stress

 Some couplings may loosen over time, damaging the drive components

Belt drives

Types of belts used in belt drives: flat belt, V belt, toothed belt

Belt drives are a fairly common sight in industrial applications. A belt drive system
consists of two pulleys and a belt (or rope). The belt firmly grips both pulleys and
transfers power from the driving shaft to the driven shaft through friction. The belt
drive works equally well for slow and very high speeds and thus finds use in high-
speed applications such as air compressors.

Just like other drives, there are many belt drive designs that are great for specific
applications. Belts can power multiple parallel pulleys and change the speed as
needed. They can also absorb shock loads to a certain extent, protecting other drive
parts. Both pulleys rotate in the same direction unless it is a cross-belt drive. There
are three main types of belts in belt drives – flat belts, V belts and toothed belts.

Flat belts are great for general-purpose applications with low to medium torque demands.
Typical applications include grinders, separators, roller conveyors, fans, water turbines, etc.
Flat belts are reversible and can transfer power from both sides. There is no wedging effect
in flat belts. This makes the energy losses negligible, and the mechanical efficiency can be
over 98%. It can handle dust and dirt reasonably well and thus, has a longer service life
compared to other alternatives.

V belts are better for medium to high torque demands. A V belt has grooves on the inside
surface that fit into wedges on the pulleys. The driving shaft pulls the belt by the grooves,
which pulls the driven pulley on the other end. Such an operation causes wedging losses,
which, in effect, decreases the efficiency of a V belt. V belts cannot handle dust and dirt as
well as flat belts.

Toothed belt, also known as timing belt, has teeth on the inside surface of the belt that fit
onto toothed pulleys or sprockets. This belt drive is used for high-power transmission and
timing applications. Toothed belts are used in automobile and motorcycle engines to power
and time camshafts.

Advantages

 Belt drives are more affordable than other drives due to low component cost and high
efficiency

 They can transmit power over long distances

 Smoother and quieter operation compared to chain drives

 They can absorb shock and vibrations

 Belt drive provides some degree of overload protection through the slipping of the belt

 Lightweight and relatively durable

 Low maintenance costs

Disadvantages

 Belt slippage can vary the velocity ratio

 Short service life if not maintained well

 Finite speed range

 They apply a heavy load on the bearings and shafts

 To compensate for wear and stretching, they need an idler pulley or some adjustment
of center distance

Chain drives

to transmit power between two components that are at a greater distance. These drives
consist of a roller chain and two or more sprockets. The driver sprocket’s teeth mesh with the
roller chain and transfer torque to the driven sprocket. Chains can be commonly seen in
power transmission in bicycles and motorcycles, but they are also quite common in industrial
machines.
They can fit into tight spaces by using idler sprockets. Chain drives are also used in
applications where timing is critical and any delay caused by slippage would result in
problems. This is why they are used in marine diesel engines, as timing chains to transfer
power from the crankshaft to the camshaft. The camshaft operates the exhaust valve and the
fuel injection timing. If the timing is off, the engine will suffer.

Advantages

 A chain drive is more compact than a belt drive and can fit into relatively tight spaces

 It can transfer torque over long distances

 Contrary to belt drives, chain drives do not slip

 One chain drive can power multiple shafts at a time

 It has high mechanical efficiency thanks to little friction

 A chain drive can work in all kinds of service environments (dry, wet, abrasive,
corrosive etc.) and at high temperatures

Disadvantages

 They are noisy and can also cause vibrations

 A chain drive cannot work with non-parallel shafts

 Some designs require constant lubrication

 Misalignment may cause the chain to slip off

 A chain drive usually needs an enclosure

 It requires an arrangement for chain tensioning in the form of a tightening idler

sprocket

Gear drives

Gear drives use gears for motion and power transmission from one shaft to another. They
consist of a driving gear (on the input shaft) and a driven gear (on the output shaft). Power
transmission from the power source to the load takes place through the meshing of the gear
teeth. Due to the many available designs, they can work in a number of orientations and
applications.

A gear drive can handle higher loads compared to a chain drive but is only suitable for short
distances, as the gears need to be in direct contact with each other. Using multiple gears in a
gear train makes it possible to change the gear ratio, rotational speed, torque and direction
as needed. Too many gears in a single system will, however, reduce mechanical efficiency.

Gear drives do not slip but they may develop some backlash over time. Backlash is the gap
between two meshing gear teeth at the pitch circle. At lower outputs, it may only result in
some minor calculation errors. But at higher power outputs, the backlash will send a shock
through the entire gear train. On occasion, it can even cause damage to the gear teeth.

Advantages

 Suitable for high mechanical power transmission applications

 Gears are sturdy and have long service lives

 Compact setup

 Gears have high efficiency and do not slip

Disadvantages

 Not suitable when distances between shafts are high, a direct connection is needed

 Prone to vibration and noise

 Metal gears are heavy and increase the weight of the machine

 They do not offer any flexibility

 They require lubrication

 Shock loads can damage gears

 Costlier than other drives (chain, belt, etc.)

 Meshing gears require precise alignment

Power screws
Vices use power screws to convert rotary motion into linear motion

Power screws, also known as lead screws (leadscrews) or translational screws, are screws
that either transmit or receive power. They are different from screw fasteners that are used to
create temporary joints in machines. Power screw consists of a screw and nut that mesh with
each other for power transmission.

In some cases, the nut is stationary while the screw moves for power transmission (screw
jack and vice). In other cases, the nut is the power source and the screw is stationary (lathe
lead screw).

Power screws are subject to considerable axial, horizontal and vertical forces in operation.
They must have sufficient strength and bearing area to withstand them.

Lead screws can be seen in action in screw jacks, lathes, vices, mechanical presses, etc.
They use the same principle as screw fasteners of converting rotational motion into linear
motion to reduce the effort required to do work. The lower the pitch, the easier it is to lift,
move or tighten objects with power screws. The most common thread profile for power
screws is a square thread, followed by acme and buttress threads.

Advantages

 Power screws are cheap and reliable as they only have a few parts
  Some lead screws have self-locking property

 It requires little to no maintenance

 Capable of lifting heavy loads

 Smooth and quiet operation

 Low-pitch screws can give highly precise measurements, which are vital in machine
tool applications (A micrometer works on the same principle)

Disadvantages

 High wear rate compared to other methods of mechanical power transmission

 Power screws have poor efficiency

 Not suitable for mechanical power transmissions with a very high torque demand

Choosing the Correct Power Transmission Method

Choosing the right power transmission method can be tricky. From the data above, it is clear
that every type has its pros and cons. The differences may be very obvious in some areas,
but subtle in others.

Sometimes, subcategories within a particular type will help improve performance in some
aspects. But if engineers work backwards from their expectations from the drive, it will
narrow down viable options and even help with the final selection.

In this section, we shall see five important power transmission factors that will help you select
the correct method for your application:

 Angle between shafts

 Distance between the prime mover and the load

 Torque

 Temperature

 Maintenance concerns

Angle between shafts

Shafts can be parallel, intersecting, non-parallel but intersecting or non-parallel non-

intersecting. Some mechanical power transmissions require that there is no relative motion
between shafts (e.g. gear, chain & belt drives). In contrast, others can handle minor
misalignment (e.g. flexible shaft couplings).

Distance between the prime mover and the load

The distance between the power source and load can further narrow down the choice.
Where there is a considerable distance between shafts, a belt drive or a chain drive can be
used. For short distances, shaft couplings and gear drives are more suitable.

Torque

For high torque applications, chain drives can be used as belt drives may slip. On the other
hand, for low torque needs, flat belt drives and power screws are better.

Temperature

Materials such as rubber and synthetic compounds are not compatible with high-temperature
environments. If such materials are used to manufacture belts in belt drives, they will start
wearing out soon.

Alternatives such as chain and gear drives are better suited to high temperatures as they can
quickly acclimatise to such environments and work efficiently. Such systems can also work
with oil cooling methods. The same oil that is cooling the engine can be used to lubricate the
drive. On the other hand, oil cooling is not possible with rubber as it will degrade the material.

Maintenance concerns

Maintenance issues such as tensioning, wear rate, alignment and lubrication can help an
engineer determine the suitable mechanical power transmission method for the application