That complex connection between shafts and torque in high-power machinery occurs through industrial flexible couplings. There's a lot to know for those in the business of making the whole system work and run smoothly. With the impact on a wide variety of industries, those in the industrial manufacturing and repair fields must be educated on a vast amount of components with shaft coupling as a significant portion of that education.

Flexible shaft coupling allows for some variation in the alignment, which is vital to both speed and accuracy. The benefits of flexible shaft couplings also include noise control by harnessing vibration within the unit.

Focus your training and education to make the most out of all that power. Consider the following:

1. Flexible coupling manufacturers produce their own educational materials for your use including technical guides, reference books and even online help.

2. Some training programs on industrial flexible shaft coupling may count as continuing education credits.

3. When it comes to flexible shaft coupling, selection can be crucial. Learn to identify the different coupling components to decipher which one would work best.

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Read articles on flexible shafts

Start your educational quest by doing some research online. Online articles can supply up-to-date information in a timely fashion as many aren't too lengthy and can be read quickly. You'll also be able to get quick access to specific information.

I recommend: Read the abstract of the article "And you thought all flexible pump couplings were the same" by Jon Mancuso at Science Direct, and then get more information from the links at the bottom of the page. Gain access to relevant articles from Coupling Corporation.

Browse the educational references from flexible shaft couplings suppliers of books

Each machine is different. That's why gaining a wide array of knowledge on many different kinds of flexible shaft couplings is ideal. Look to both manufacturers and suppliers to provide technical manuals and other reference guides. Many different books can also be purchased and kept on hand to answer questions as they arise.

I recommend: "Couplings and Shaft Alignment" from John Wiley & Sons provides an overview of shafts, couple selection and shaft alignment issues. Order GlobalSpec's book "Precision Couplings and Line Shafts" whih discusses the basics in shaft design and functionability.

Attend targeted training on industrial flexible shaft couplings

Many find that hands-on learning can be of a real benefit. Some even learn best that way. Find ways to get down and dirty with the very parts you've been learning about. You'll be able to connect the dots in your mind as to how each piece works and fits together to complement the whole.

I recommend: The International Society of Automation provides training on industrial drives, shaft joining and coupling devices. Check out the Manufacturing Engineering Technology program offered at Apollo Career Center.

Flexible shaft couplings distribute the torque between two connected shafts or a shaft and another moving part such as a flywheel or a universal joint. A flexible shaft coupling, in contrast to a rigid coupling, can accommodate up to 3 degrees of misalignment in the coupled shafts. That's especially critical in high speed or precision applications. In addition, industrial flexible couplings help dampen vibration and reduce noise.

Suppliers of flexible shaft couplings provide motion control and power transmission solutions for a wide variety of industrial applications, including power generation, petrochemicals, steel, mining, food production and printing. Use flexible shaft couplings in fans, blowers, turbines and anywhere you need to distribute torque on a driveline. Look for flexible coupling manufacturers that provide:

1. Jaw-type flexible shaft couplings

2. Gear couplings, which have the highest tolerance for shaft misalignment

3. Steel grid flexible shaft couplings

4. Torsional rubber shaft coupling and disk coupling styles, designed to distribute torque between a shaft and a flywheel

5. Specialty or custom flexible shaft couplings

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Choose jaw-style flexible shaft couplings for easy maintenance

Jaw shaft couplings use a rubber insert, sometimes called a spider because of its shape, between two interlocking hubs. Jaw-style couplings come in straight, curved and in-shear varieties. They're self-lubricating, and the inserts can be replaced without touching either hub, making maintenance on the fly a snap.

I recommend: DieQua's Zero Backlash jaw couplings are available in eight models, with aluminum hubs standard and stainless steel optional. Lovejoy, a leading flexible coupling manufacturer, offers jaw in-shear couplings popular for use in gearboxes, fans, compressors and blowers. Turn to OEP Couplings for jaw couplings that keep the drive hub turning the driven hub, even when the insert fails.

Select gear style flexible shaft couplings for maximum tolerance

You want flexible couplings, not flexible shafts, so choose gear couplings for situations with high misalignment potential. Gear couplings with interlocking teeth have the highest tolerance, handling up to 3 degrees of misalignment without vibration.

I recommend: Choose from Magnaloy's nine models of magnesium gear couplings. Both in-stock and custom orders ship within 3 to 10 days. Order an industrial flexible shaft coupling from Reid Supply Company for low vibration and high misalignment tolerance.

Get grid flexible shaft couplings for smooth torque distribution

Grid flexible couplings use a gridded insert that slides along slots in the hubs. Grid style couplings can only handle one-third of a degree of misalignment, but they offer excellent torque distribution.

I recommend: Check out the David Brown Series X grid flexible couplings at Cone Drive Operations. They carry a 5-year lubrication warranty. Falk Steelflex grid couplings from Rexnord offer an economical alternative to gear-style flexible shaft couplings. This flexible coupling manufacturer boasts the largest selection on the market.

Use a torsional rubber shaft coupling for flywheels and universal joints

Torsional couplings connect drive shafts to other devices such as universal joints and flywheels, or provide torsional stability in three dimensions.

I recommend: ROTEX torsionally flexible couplings from KTR transmit torque even over very small shaft distances. Use the online selection tool to create your own DXF drawings. Stromag's Perimax flexible couplings let you easily connect a shaft to a flange.

Contact flexible shaft couplings suppliers for new designs or custom orders

Manufacturers of flexible shaft couplings are always making improvements in the product. And if you don't find what you need from flexible shaft couplings suppliers' stock, you can always customize your order.

I recommend: Frontline's patented Big Boy couplings use an innovative double-engagement design that keeps the hubs floating around precisely machined steel pins. If you want to make innovations of your own, contact The Rowland Company, a veteran-owned business that offers custom design and fabrication of industrial flexible couplings.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Stock up on replaceable rubber shaft coupling inserts when you order industrial flexible couplings.

A flexible shaft coupling is a device used for transmitting mechanical power when the drive and driver shafts have radial, axial or angular misalignment. For selecting the most suitable flexible shaft coupling, you must understand the working of the different types of flexible shaft coupling products available in the market.

If you want to buy a flexible shaft coupling, you will need to understand various technical specifications for your application requirements before communicating with the suppliers of flexible shaft couplings. This guide covers some of the terms related to flexible shaft couplings, such as torque, RPM, shaft alignment and Oldham coupler.

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Torque

Torque is defined as the measure of force applied to an object to produce rotational motion. Torque is determined by multiplying the applied force by the distance from the pivot point to the point where the force is applied.

I recommend: You can read through detailed information about torque at the Department of Physics at University of Guelph.

RPM (Revolutions Per Minute)

Revolutions per minute (RPM) is the number of rotations completed by the shaft in one minute around a fixed axis. It is most commonly used as a measure of rotational speed or angular velocity of mechanical components.

I recommend: Opto 22, a manufacturer of hardware and software products, provides information about RPM and RPM measurement techniques.

Shaft alignment

Shaft alignment is the positioning of the rotational centers of two or more shafts such that they are co-linear when the machines are under normal operating conditions.

I recommend: Machine Diagnostics Inc. (PDF), a provider of machine maintenance services, explains the importance of shaft alignment.

Backlash

Backlash (sometimes called lash or play) is the clearance between meshing components. Maintaining optimum backlash is very important, as a larger backlash affects the transmission efficiency of a coupling.

I recommend: R + W America, a manufacturer of flexible shaft couplings, torque limiting couplings and line shafts, provides information about backlash error.

Torsional stiffness

Torsional stiffness is the measure of resistance of a shaft to the twisting force. Since the purpose of a flexible shaft is to accurately transmit rotary motion with minimum twisting, a high torsional stiffness value is generally desirable.

I recommend: Huco-Dynatork, a manufacturer of couplings, provides information about torsional stiffness.

Oldham coupler

An Oldham coupler is a flexible shaft coupling product that is useful for connecting parallel shafts. It has three components. The first disc component is connected to the driver shaft, another disc component is connected to the drive shaft and a middle disc component rotates around its axis to transmit power between the two shafts.

I recommend: To learn about an Oldham coupler, its advantages and disadvantages, read through information available at OEP Couplings, a reputable supplier of shaft coupling products.

Universal joint

A universal joint (also called a Cardan joint) is another shaft coupling product that is useful for connecting parallel shafts where the alignment between the shafts may vary during the rotary motion. These joints are useful for various mechanisms in automotives.

I recommend: To learn more about universal joints, their types and applications, read through information at GlobalSpec.

Flexible shaft couplings applications and uses vary. Flexible shafts are uniquely designed to address various load conditions. No one shaft coupling can meet all needs. Therefore, the construction of flexible shaft couplings is designed to handle one or more application requirements.

Flexible shaft couplings are required for the operation of most mechanical systems including motors, ball screws, gears and other components that require shafting. They are used by power plants, processing plants and refineries. To choose the best shaft coupling to fit your needs, it’s important that you gain an in-depth understanding of various shaft coupling application conditions. The following tips will help you obtain knowledge about flexible shaft couplings applications and uses:

1. Select shaft couplings specifically for your application.

2. Determine the benefits of using low and high torque shaft couplings.

3. Evaluate shaft coupling movement for optimal performance.

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Use the right flexible shaft to meet your needs

For hand operated or intermittent power applications, flexible shaft couplings suppliers produce products without casings. Casings are non-metal or metal sleeves designed to protect the shaft and keep the application lubricated. Backlash shaft couplings are used when position precision is not necessary for optimal operation of the mechanical system. However zero backlash shaft couplings reduces the jarring reaction that can be caused by play in the coupling.

I recommend: Find out more about when to use which a flexible shaft coupling at R+W. You can also evaluate various types of flexible shaft couplings at OEP Couplings.

Know which flexible shaft coupling torque strength is best for your job

The strength and power of flexible couplings is based on torque and horsepower which measures the ability of shaft couplings to transport a specific load multiple times. Horsepower is measured by the torque and speed of the shaft coupling. High torque flexible shafts are highly durable and flexible. Low torque couplings or torque limiters can disengage motor drives of shaft couplings to prevent damage from overload.

I recommend: Find out more about high torque couplings at Coupling Corporation of America. Read more about torque limiting couplings at Zero-Max.

Ensure industrial flexible shaft couplings have proper movement

Lateral and axial flexibility are application factors that should be carefully considered when using shaft couplings. Flexible coupling manufacturers design these products so that there is restricted movement with lateral or axial forces. Lateral movement is a key factor in the functionality of disk brake rotors or indicators used to determine the sidewall movement of tires. Axial movement is the type of movement seen with bench grinders which move along the center of a shaft.

I recommend: Learn more about the flexibility of shaft couplings at Lovejoy. You may also find out about flexible shaft couplings at Heavy Equipment Machinery Information.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  In addition to torque and horsepower and shaft coupling flexibility, you should also be sure to consider several other flexible shaft couplings applications and uses before making a final decision. These factors include shaft misalignment, service conditions, backlash and flexibility of the shaft's torsion.