When Should I Replace A Coupling?

Stan Riddle, VibrAlign

In our shaft alignment training classes, we typically see some coupling inserts that are well
past their prime. In many of these instances, mechanics were not quite sure when a coupling
insert (or an entire coupling) should be replaced. So lets look at some common coupling
types, and discuss when replacement should be needed.

But before we do, its important to note that coupling inserts are meant to be the weak link
in most power transmission systems. That is to say the coupling insert should be designed to
fail before damage can be caused to other components. Machine design engineers should also
choose a coupling type which can handle the required start-up torque, transfer power for the
necessary period of time, and lend itself to quick replacement when needed. Couplings should
also be tolerant of minimal amounts of misalignment.

Jaw-type couplings (often called spiders)

have been around for many years. They are inexpensive, do not require lubrication, and have
a good ratio of horsepower to diameter. For maximum life, they do require precision
alignment, and proper axial spacing.

The most common failure mode for this type of coupling is damaged or missing legs, as
shown in the photo. But they can be susceptible to cracking before this type of failure occurs.
Since they can be obtained in many different types of materials, it is advisable to work with
your distributor, to get the best insert type for your application.

A visual inspection of the spider is recommended to minimize the risk of unexpected failure.
When these inserts fail catastrophically, the hub jaws will continue to transmit power for a
short time.

S-Flex couplings are another very common

type of coupling insert, sharing many of the same characteristics as jaw couplings. Two of the
most common failure modes are:

shearing, as shown in this photo. This is normally caused by either misalignment,

improper axial spacing, or both.
twisting, where the insert twists over time, normally due to both start-up and
running torque.
A regular inspection for these two types of coupling damage is recommended.

Clamshell type elastomeric couplings have a

very effective horsepower/diameter ratio. While the couplings can tolerate misalignment, their
stiffness means that misalignment forces can cause excessive loading of bearings and seals.
Precision alignment is recommended. These couplings can also be specified with different
materials, depending on load and temperature. Accurate axial spacing is recommended.
Damage on this coupling type is usually noted by torsional cracking of the elastomer.

Grid couplings do require lubrication, and are

generally tolerant of slight misalignment. As well as precision alignment and proper axial
spacing, these couplings do require occasional lubrication (using the recommended grease
type) and inspection.

Inspections should also include a visual inspection of the grid, looking for indentations or
cracking, and inspection of the hub teeth for wear. Excessive misalignment or improper axial
spacing of this coupling can cause the grid to break.

It should be noted that, for most flexible couplings, the manufacturers maximum allowable
misalignment value is the maximum misalignment the coupling can tolerate before
catastrophic failure occurs, not the amount it should be aligned to. Precision alignment is
recommended for any coupling.