Improve Power Transmission: Square Insert Breaking Problem

[rashidin]

Hi all,
I am currently assigned to improve a power transmission problem. The square insert joining the clutch system of a motor to my power transmission system is always broken. Based on my initial calculations, the square insert is able to withstand up to 20 times more torque than the motor's highest rated torque (based on it power and max rpm).

I suspects that it is broken due to shocks and pulse exerted on the power transmission system. What do you guys think?

 

[schip666!]

Would have to see the materials and damage to even form an uninformed opinion -- but shock is probably the culprit. Is the motor an internal combustion kinda thing? There could be a very high accel right after each ignition. Some motorcycles I've hacked have springs or even rubber-bumpers in the clutch basket where it connects to the primary drive to act as shock absorbers.

Otherwise use a bigger square. Or a less brittle material (presuming you have sheering rather than rounding of the corners...).