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1. Coupling Method: The assembly employs a Joe Cup as a flanged bushing to connect two carbon fiber (CF) tubes of different outer diameters (ODs).
2. Component Specifications:
- Larger Tube: OD of 40 mm, ID of 37 mm.
- Smaller Tube: OD of 36 mm, ID of 33 mm.
3. Joe Cup Construction:
- Material and Dimensions: The Joe Cup consists of a strap or tubular webbing approximately 300 mm in length.
- Flange Creation: The ends of the strap or tubular webbing are folded and sewn to form a loop that captures and bonds tiny rods. These rods create the flange of the Joe Cup.
- Central Region: The central region of the strap or webbing is designed to be pushed by the smaller CF tube during insertion into the larger CF tube.
4. Coupling Mechanism:
- The Joe Cup’s flange (created by the captured tiny rods) prevents the bushing from sinking into the larger diameter tube and maintains the axial alignment of the tubes.
- Insertion of the smaller tube into the larger tube stops when the tiny rods (flange) reach the visible join line of the two tubes.
- The Joe Cup remains in place due to the axial compression of the tubes, ensuring that the rods remain at the join line and the connection is secure.
5. Fit and Tolerances:
- The Joe Cup’s design ensures a precise and stable connection between the two tubes, preventing wobble and ensuring alignment.
Some nomenclature clarification surrounding Joe Cups:
Prompt: Does "flanged bushing" as an engineering term address that the bushing not only gap fills but also has a bottom that limits insertion?
Response: The term "flanged bushing" generally implies that the bushing has a flange or projection that serves a few purposes:
1. Gap Filling: It helps to fit or fill the gap between two components, ensuring a snug connection.
2. Limiting Insertion: The flange acts as a physical barrier or stop to prevent further insertion beyond a certain point.
However, "flanged bushing" may not explicitly convey the function of limiting insertion. To clarify that the bushing also prevents deeper insertion, you might use additional descriptors like:
- "Flanged Bushing with Depth Stop": This indicates that the bushing has a flange designed specifically to limit how far one component can be inserted into another.
- "Flanged Bushing with Internal Stop": This highlights that the bushing's flange or internal feature prevents deeper insertion.
- "Flanged Bushing with Axial Stop Feature": This emphasizes the bushing's role in preventing excessive axial movement.
In summary, while "flanged bushing" does imply some degree of limiting function, adding specific terms like "depth stop" or "axial stop feature" can more clearly communicate that the bushing also prevents excessive insertion.
Prompt: The inserted end of the CF tube should be plugged to give some non-sharp interface with the Joe Cup's strap or tubular webbing. The plug would have a radius edge that would not cut the strap or tubular webbing. Permanently putting such plug end on just one end of the CF tube would keep the interior of the tube available for tiny packing of other tubes or parts inside the one-end-plugged tube.
Response: To address this, the CF tube should have a plug installed at the inserted end to ensure a non-sharp interface with the Joe Cup's strap or tubular webbing.
1. Plug Design: The plug should feature a radius edge to avoid cutting or damaging the strap or webbing during insertion.
2. Installation: The plug is permanently attached to one end of the CF tube, which allows the other end of the tube to remain open for tiny packing of additional tubes or parts.
3. Functionality: This design helps to protect the strap or webbing from abrasion while maintaining the interior of the tube for compact storage.
This approach ensures both the durability of the coupling mechanism and the efficient use of space for packing.
Prompt: During flight force variations one might consider a Joe Cup that is of a strapping or tubular webbing that is elastic. Then when a meta spar of spar segments are given a sudden increase of axial compression from a change in flight loadings, the "give" of the elastic Joe Cup might be a favorable deal.
Response: Considering an elastic Joe Cup could be beneficial for accommodating flight force variations. Here's how it could work:
1. Elastic Material: The Joe Cup could be made from elastic strapping or tubular webbing that provides some flexibility.
2. Response to Axial Compression: When the meta spar experiences a sudden increase in axial compression due to changes in flight loadings, the elastic nature of the Joe Cup would allow it to absorb and accommodate these variations.
3. Benefits: The "give" of the elastic Joe Cup might reduce the impact of sudden load changes and enhance the overall stability and durability of the connection during flight.
This approach can provide a more forgiving interface, potentially improving the performance and longevity of the coupling mechanism under dynamic conditions.
Pros of an Elastic Joe Cup:
1. Accommodates Load Variations: The elasticity of the Joe Cup can help absorb and adapt to changes in axial loads, which is particularly beneficial during dynamic conditions like flight.
2. Reduces Stress Concentrations: The elastic material can help distribute forces more evenly across the coupling, reducing stress concentrations and potential points of failure.
3. Improves Flexibility: Elastic strapping or webbing allows for a more flexible connection, which can enhance the system's ability to handle movement and vibrations.
4. Enhances Durability: By providing a cushioning effect, the elastic Joe Cup may reduce wear and tear on both the bushing and the connected components, potentially extending the lifespan of the coupling.
5. Mitigates Shock Loads: The elastic nature can help in dampening shock loads or sudden force changes, making the system more resilient to abrupt impacts or load fluctuations.
6. Prevents Structural Damage: The flexibility of the elastic Joe Cup can minimize the risk of damaging the connected components or the Joe Cup itself during sudden load changes.
7. Improves System Stability: The ability to adapt to varying loads can contribute to overall system stability and performance, particularly in applications subject to frequent or significant force variations.
This approach leverages the properties of elastic materials to offer enhanced performance and resilience in dynamic environments.
