Insertion element for inserting and positioning a shaft element, system with the insertion element, a method for assembling the system, and a method for replacing a component in the system

Abstract

Insertion element (1) for inserting (150) and positioning a shaft element (2) into a sleeve (3), comprising a hollow cylindrical base body (4) for guiding the shaft element (2) into the sleeve (3) during an assembly operation, wherein the outer circumference (5) of the hollow cylindrical base body (4) has a first section (6) and a second section (7), wherein the second section (7) is associated with a first end (8) of the hollow cylindrical base body (4) and wherein the second section (7) has a support collar (9) for sealing, and wherein the inner circumference (10) of the hollow cylindrical base body (4) has an assembly aid (11) which serves to guide and support the shaft element (2) during the assembly operation and is non-contacting with the shaft element (2) in the operating state, characterized in thatthat the hollow cylindrical base body (4) is two-part and has an outer ring (15) and an inner ring (16) connected to the outer ring (15) (17), which is at least partially the assembly aid (11).

Description

[0001] The invention relates to an insertion element for inserting and positioning a shaft element, a system with the insertion element, a method for assembling the system, and a method for replacing a component in the system.

[0002] In the automotive industry, it is common practice to guide a driveshaft into a gearbox housing via an axle tube. The axle tube serves to protect the driveshaft from external influences and to protect surrounding components from the driveshaft's movement during operation. The axle tube is inserted into an opening in the housing and connected, creating a gap between the axle tube and the housing at the inserted end. Due to the moisture in the air inside the axle tube, corrosion occurs, particularly in these gaps, affecting both the axle tube and the housing, thus reducing the service life of the components.

[0003] Simultaneously, when inserting the shaft into an axle tube or sleeve, misalignment occurs due to the shaft's length, making insertion into the housing or an opening in the housing difficult. For this reason, insertion aids are frequently used to center the shaft as it is inserted through the sleeve, preventing the shaft from touching or damaging the gearbox seal. Such insertion aids are described, for example, in US 4,658,670 A, DE 35 03 602 C1, DE 22 46 268 A, and DE 103 15 598 A1. Known solutions involve inserting a loose, i.e., non-fixed, guide into the sleeve or axle tube. These guides can shift within the sleeve during operation and, during disassembly (i.e., removing the shaft from the housing and axle tube), can become jammed, making removal of the shaft difficult or impossible without damaging other components.

[0004] It is therefore an object of the present invention to overcome at least one of the disadvantages described above, at least partially. In particular, it is an object of the invention to increase the protection against corrosion in a housing and the connected components and to provide tolerance compensation between the components and the housing.

[0005] The foregoing problem is solved by an insertion element having the features of independent claim 1, by a system having the features of independent claim 7, and by respective methods having the features of independent claims 8 or 12. Further features and details of the invention will become apparent from the dependent claims, the description, and the drawings. Features and details described in connection with the insertion element according to the invention naturally also apply in connection with the system according to the invention and / or in connection with the method according to the invention, and vice versa, so that the disclosure of the individual aspects of the invention is always, or can always be, mutually interdependent.

[0006] According to the invention, an insertion element is provided for inserting and positioning a shaft element into a sleeve, with a hollow cylindrical base body for guiding the shaft element into the sleeve during an assembly process, wherein the outer circumference of the hollow cylindrical base body has a first section and a second section, wherein the second section is associated with a first end of the hollow cylindrical base body and wherein the second section has a support collar for sealing, and wherein the inner circumference of the hollow cylindrical base body has an assembly aid which serves to guide and support the shaft element during the assembly process and is non-contacting with the shaft element in the operating state.

[0007] The support collar of the second section is positioned in the operating state, i.e., when the shaft element is inserted and driven, so that it is in butt with both the housing and the sleeve to seal this area. This prevents moisture, such as humidity present in the sleeve, from entering a gap between the sleeve and the housing and causing corrosion. The support collar thus seals the area where the sleeve and the housing meet, thereby reducing corrosion. This is particularly advantageous when the housing or sleeve has a machined surface, as this is especially susceptible to corrosion. The support collar can extend 50 to 100%, preferably 60 to 90%, and more preferably 65 to 80%, of the longitudinal extent of the second section.

[0008] Another advantage of the insertion element with support collar is that the support collar ensures the insertion element remains in a fixed position during the assembly and disassembly of the sleeve and gearbox, or when inserting the shaft element. This allows the shaft element to be pulled out of the sleeve and housing without the insertion element shifting or becoming misaligned. The support collar also compensates for tolerances between the housing and the sleeve.

[0009] The inner mounting aid can conform to a contour that helps guide, support, and center a shaft element during the assembly process in such a way that no components in the housing are displaced or damaged. For example, if the housing is a gearbox housing, the mounting aid guides and centers the shaft element into an opening in the housing in such a way that the existing seal for the oil-tight sealing of the housing is not damaged or displaced.

[0010] A monolithic support element with a support collar is easy to handle and simplifies the assembly of systems or devices where shaft elements or cylindrical elements are guided within a sleeve to an opening in a housing. Furthermore, its shape and the available material options allow for quick and cost-effective manufacturing. For example, the insertion component can be designed for injection molding.

[0011] Within the scope of the invention, it can be advantageous for the assembly aid to have a third and a fourth section. The third and fourth sections have different shapes. The third section is associated with a second end of the hollow cylindrical base body that is opposite the first end.

[0012] The term "gradient" refers to the fact that their contour or geometric design differs. This allows for optimal fulfillment of the guiding and centering tasks, as the third section can initially serve to insert the shaft element, and the fourth section can then take over the supporting function.

[0013] Since the third and fourth sections are designed differently, they can be easily adapted to different shaft element dimensions. The diameter, but also the length of the shaft element, plays a crucial role. Thus, the length of the assembly aid, i.e., the sum of the lengths of the third and fourth sections, can be 50 to 100%, preferably 60 to 90%, and more preferably 70 to 80%, of the total length of the insertion element. The fourth section can have a length of 30 to 70%, preferably 40 to 60%, and more preferably 45 to 55%, of the length of the assembly aid.

[0014] Within the scope of the invention, it is conceivable that the course of the third section and / or the fourth section is conical, cylindrical, or parabolic.

[0015] For insertion, it is particularly advantageous if the third section is conical or parabolic. For support, it is advantageous if the fourth section has a cylindrical profile. The conical or parabolic profile can also be achieved through different overlapping radii. The continuous reduction in diameter optimally positions the shaft element first in the support position and, with further insertion into an opening of a housing, pushes it into its final or operating position.

[0016] Within the scope of the invention, it may be provided that a sealing material is applied to the support collar and / or second section and / or the first section of the hollow cylindrical base body.

[0017] The additional sealing material provides an extra seal between the sleeve or housing and the air inside the sleeve. This sealing material is deformable, particularly compressible, and can therefore compensate for tolerances between the insertion element and the sleeve or between the insertion element and the housing.

[0018] Suitable sealing materials are primarily those that can be sprayed onto the support collar and / or the second section and / or the first section of the hollow cylindrical base body and adhere well to the base material of the insertion element. Ethylene propylene diene monomer rubber (EPDM), for example, is well-suited as a sealing material.

[0019] The sealing material can be sprayed on section by section and / or circumferentially, that is, onto the circumferential surface of the respective section of the insertion element. This allows for the compensation of global as well as local tolerances.

[0020] The hollow cylindrical base body is designed to be two-part, comprising an outer ring and an inner ring connected to the outer ring, which at least partially serves as an assembly aid.

[0021] In this context, "two-part" means that the insertion element consists of at least two parts, wherein the outer ring is a first part and the inner ring is a second part.

[0022] This is particularly advantageous during assembly, as only the outer ring can be permanently installed initially, and the inner ring can be installed just before the shaft element is inserted. This allows for more installation space during assembly and enables repair of the insertion element, since at least the inner ring can be designed to be reversible.

[0023] The outer ring comprises at least the first and second sections of the outer circumference as well as the support collar of the insertion element. The inner ring comprises at least the fourth section, i.e., part of the assembly aid.

[0024] Depending on the embodiment and the required inner contour, the third section can be formed on either the outer or the inner ring. If the outer ring has the third section, it is conceivable that the inner ring has only the fourth section or an additional fifth section. The fifth section is then arranged between the third and fourth sections and can continue the contour of the third section or have a different shape compared to the third and fourth sections, which in turn can also be conical, parabolic, or cylindrical.

[0025] The advantage of the two-part design of the insertion element is also its assembly and flexibility of use; the outer ring is always a standard part for the respective housing, while the inner ring can be easily adapted to the shaft element to be inserted.

[0026] It is also conceivable that the connection between the outer ring and the inner ring is a form-fit and / or force-fit and / or material-fit connection, in particular a clip connection or a screw connection.

[0027] It is particularly advantageous if the connection is detachable to allow for easy installation or replacement in case of repair. Good accessibility of the connection is beneficial for installation and replacement, which is why the connection is usually located at the first end of the insertion element.

[0028] The simplest solution is a clip connection, wherein the outer ring has a groove, preferably a circumferential groove, and the inner ring has a spring fitting into the groove, preferably a circumferential spring with spaced-apart gaps. It is also conceivable that a further support element associated with the first end is provided on the inner ring, which bears against the inner circumference of the outer ring.

[0029] Within the scope of the invention, it is optionally possible that the hollow cylindrical base body is made of a plastic or a metal or a metal-reinforced plastic or fiber-reinforced plastic.

[0030] This allows for simplified manufacturing of the insertion element and ensures a certain strength necessary for insertion, support, and withdrawal.

[0031] The use of plastics such as polyethylene terephthalate, polysulfone, polyamide, or polyethylene is particularly advantageous because they are corrosion-resistant and easy to process. It is also beneficial to use injection-moldable plastics, as this allows for the cost-effective production of many parts. If the hollow cylindrical body is made of two parts, the outer and inner rings can be made of the same or different materials.

[0032] The above problem is further solved by a system according to the invention comprising a housing, in particular a gearbox housing, a sleeve, in particular an axle tube, and a shaft element and an insertion element, in particular an insertion element as described above, wherein the insertion element is arranged on the housing and the sleeve in such a way that the sleeve is sealed at least partially against the housing and wherein a shaft element is guided through the sleeve and the insertion element into the housing.

[0033] This system exhibits reduced susceptibility to corrosion. Corrosion protection is achieved simply and cost-effectively through the insertion element.

[0034] A system that provides a press fit between the sleeve and the housing is particularly advantageous and safe for operation.

[0035] The above-mentioned problem is further solved by a method according to the invention for assembling the above-mentioned system. In a first step, an insertion element as described above is inserted into a housing. In a second step, the sleeve is positioned in the housing so that the support collar of the insertion element is arranged between the housing and the sleeve to create a sealing effect. Subsequently, a shaft element is inserted into the housing through the insertion element. Since an opening in the housing and the insertion element are arranged concentrically to each other, the shaft element is centered and supported during the insertion process.

[0036] Furthermore, the invention may provide for the sleeve to be pressed into the housing. This creates a secure connection between the sleeve and the housing and protects the shaft element, which moves during operation, from external influences. Additionally, this compresses the support collar of the insertion element, which enhances the sealing effect and improves the positioning of the insertion element.

[0037] With regard to the present invention, it is conceivable that a sealant is sprayed onto the support collar and / or the first section and / or the second section of the insertion element before the insertion element is inserted.

[0038] This sealant enhances the sealing effect of the insertion element. At the same time, it allows for the simple compensation of tolerances. These tolerances, or play, can exist between the insertion element and the sleeve and / or the housing, or simply between the housing and the sleeve. The compressible sealant can penetrate existing or emerging gaps to such an extent that movement is prevented and a seal is established.

[0039] In a method according to the invention, the insertion element is provided to be two-part, wherein an outer ring is inserted into the housing and pressed in, and wherein an inner ring is only connected to the outer ring after pressing in, in particular by clipping or screwing in.

[0040] This allows for the repair of the insertion element and facilitates the assembly of the individual components. The outer ring can be designed as a standard part, while the inner ring, or the insertion aid partially formed by the inner ring, can be adapted to the dimensions of the respective shaft element.

[0041] The above problem is further solved by a method according to the invention for replacing a component, in particular a seal in a housing, in a system mentioned above, in the following steps: - Opening the housing, especially the gearbox housing, - Removal of components located in the housing, in particular bearings and / or gears, - Removal of a shaft element, in particular a drive shaft, wherein the shaft element is pulled on the side of the sleeve, - Removal of the component to be replaced, - Inspection of the insertion element, in particular an insertion element described above. - Inserting the replaced component, - Inserting the shaft element into the housing via the sleeve and the insertion element, - Inserting the removed components, - Closing the case.

[0042] Within the scope of the invention, it may be provided that, in the case of a two-part insertion element, the inner ring is replaced during inspection.

[0043] For this purpose, the inner ring can be unclipped or unscrewed.

[0044] Further advantages, features, and details of the invention will become apparent from the following description, in which several embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description can be essential to the invention individually or in any combination. The invention is illustrated in the following figures: Fig. 1 Schematic representation of a monolithic insertion element not belonging to the claimed invention, Fig. 2 Schematic representation of a two-part insertion element according to the invention, Fig. 3 Schematic representation of a system according to the invention comprising a housing, a sleeve, a two-part insertion element and a shaft element, Fig. 4 Schematic representation of a method according to the invention for assembling the system, Fig. 5 Schematic representation of a method according to the invention for replacing a component.

[0045] In Fig. 1 and Fig. Figure 2 shows an insertion element 1 for inserting and positioning a shaft element 2 into a sleeve 3. The insertion elements 1 of the Fig. 1 and Fig. 2 have a hollow cylindrical base body 4 for guiding the shaft element 2 into the sleeve 3 during an assembly process. The outer circumference 5 of the hollow cylindrical base body 4 has a first section 6 and a second section 7, wherein the second section 7 is associated with a first end 8 of the hollow cylindrical base body 4 and wherein the second section 7 has a support collar 9 for sealing. The inner circumference 10 of the hollow cylindrical base body 4 has an assembly aid 11 which serves to guide and support the shaft element 2 during the assembly process and is non-contacting with the shaft element 2 in the operating state.

[0046] The in Fig. The insertion element 1 shown in Figure 1 is a single piece, i.e., monolithic, and made of a fiber-reinforced plastic, here polyamide. In this embodiment, the assembly aid 11 has a third section 12 and a fourth section 13. The third section 12 and the fourth section 13 have different shapes. The third section 12 is associated with the second end 14 of the hollow cylindrical base body 4. The third section 12 is conical, and the fourth section 13 is cylindrical.

[0047] In another embodiment ( Fig. 2) The hollow cylindrical base body 4 of the insertion element 1 is two-part. It has a first part, the outer ring 15, and a second part, the inner ring 16. The outer ring 15 is made of fiber-reinforced plastic, here polyamide, and the inner ring 16 is made of a plastic. The outer ring 15 is connected 17 to the inner ring 16. In this case, it is a clip connection 18, meaning that the outer ring 15 has a circumferential groove 19 into which a circumferential spring 20 with spaced-apart gaps is clipped to create the secure connection 17 between the outer ring 15 and the inner ring 16.

[0048] In the embodiment according to Fig. In the outer ring 15, the third section 12 and the inner ring 16, the fourth section 13, as well as the intermediate fifth section 21 of the inner circumference 10 or the assembly aid 11, are designed to facilitate insertion and support, ensuring that the shaft element 2 is centered during the assembly process, i.e., when the shaft element 2 is inserted. Both the third section 12 and the fifth section 21 are parabolic, while the fourth section 13 is cylindrical.

[0049] To further improve corrosion protection and to compensate for tolerances, the insertion element 1 is designed according to... Fig. 2. A sealing material 22 is applied to the support collar 9. For this purpose, ethylene propylene diene monomer rubber (EPDM) can be sprayed onto the support collar 9.

[0050] In Fig. 3 is a system 23 with a housing 24, in particular a gearbox housing 25, a sleeve 3, in particular an axle tube 26, and a shaft element 2 and an insertion element 1 according to Fig. Figure 2 shows that the insertion element 1 is arranged on the housing 24 and the sleeve 3 such that the housing 24 is sealed at least partially against the sleeve 3. The shaft element 2 is guided into the housing 24 through the sleeve 3 and the insertion element 1.

[0051] In Fig. 4 is a method 100 for assembling the system 23 according to Fig. 3 is shown. The following steps are performed: - Spraying 110 of the sealant onto the support collar 9 of the outer ring 15 of the two-part insertion element 1, - Inserting 120 of the outer ring 15 of the insertion element 1, - Arrange 130 of the sleeve 3 into the housing 24 so that the support collar 9 of the insertion element 1 is positioned between the housing 24 and the sleeve 3 to create a sealing effect, - Connecting 140, in particular clipping in, the inner ring 16 of the insertion element 1, - Inserting 150 a shaft element 2 through the insertion element 1 into the housing 24.

[0052] In this embodiment, "arranging 130" refers to pressing the sleeve 3 into the housing 24. This includes both inserting 120 of the outer ring 15 and arranging 130 or pressing the sleeve 3 in the insertion direction ER.

[0053] In Fig. Section 5 describes the method 200 for replacing a component, in particular a seal, in a housing 24 in the system 23 described above. It comprises the following steps: - Opening 210 of the housing 24, in particular the gearbox housing 25, - Removal 220 of components located in housing 24, in particular bearings and / or gears, - Removal 230 of a shaft element 2, in particular drive shaft 27, wherein the shaft element 2 is pulled on the side of the sleeve 3, - Removal of 240 of the component to be replaced, - Control 250 of the two-part insertion element 1, - Replacement of the inner ring 16 of the insertion element 1, 260 - Inserting the replaced component 270, - Inserting the shaft element 280 via the sleeve 3 and the insertion element 1 into the housing 24, - Inserting 290 of the removed components, - Close 300 of the housing 24. Reference symbol list 1 Insertion element 2 wave element 3 Sleeve 4 hollow cylindrical base bodies 5 outer circumference 6 first section 7 second section 8 first end 9 strapless collars 10 Inner circumference 11 Assembly aid 12 Third Section 13 Fourth Section 14 Second Ending 15 Outer ring 16 Inner Ring 17 connection 18 clip connection 19 Nut 20 springs 21 Fifth Section 22 Sealing material 23 System 24 cases 25 Gearbox housings 26 axle tube 27 Drive shaft ER insertion direction 100 assembly methods 110 Injections Insert 120 130 Order 140 Connect 150 Introduce 200 methods for exchange 210 Open 220 Removal of components from housing 230 Removal of shaft element 240 Removal of component to be replaced 250 checks 260 exchange 270 Inserting replaced component 280 Insert wave element 290 Inserting the components into the housing 300 Close

Claims

[1] Insertion element (1) for inserting (150) and positioning a shaft element (2) into a sleeve (3), comprising a hollow cylindrical base body (4) for guiding the shaft element (2) into the sleeve (3) during an assembly operation, wherein the outer circumference (5) of the hollow cylindrical base body (4) has a first section (6) and a second section (7), wherein the second section (7) is associated with a first end (8) of the hollow cylindrical base body (4) and wherein the second section (7) has a support collar (9) for sealing, and wherein the inner circumference (10) of the hollow cylindrical base body (4) has an assembly aid (11) which serves to guide and support the shaft element (2) during the assembly operation and is non-contacting with the shaft element (2) in the operating state, characterized by, that the hollow cylindrical base body (4) is two-part and has an outer ring (15) and an inner ring (16) connected to the outer ring (15) (17), which is at least partially the assembly aid (11). [2] Insertion element (1) according to claim 1, characterized by , that the assembly aid (11) has a third section (12) and a fourth section (13), wherein the third section (12) and the fourth section (13) have different profiles and wherein the third section (12) is associated with a second end (14) of the hollow cylindrical base body (4). [3] Insertion element (1) according to claim 2, characterized by , that the course of the third section (12) and / or the fourth section (13) is conical or cylindrical or parabolic. [4] Insertion element (1) according to any one of the preceding claims, characterized by, that a sealing material (22) is applied to the support collar (9) and / or the second section (7) and / or the first section (6) of the hollow cylindrical base body (4). [5] Insertion element (1) according to any one of the preceding claims, characterized by , that the connection (17) between the outer ring (15) and the inner ring (16) is a form-fit and / or force-fit and / or material-fit connection (17). [6] Insertion element (1) according to any one of the preceding claims, characterized by , that the hollow cylindrical base body (4) is made of a plastic or a metal or a metal-reinforced plastic or fiber-reinforced plastic. [7] comprising a housing (24), a sleeve (3), a shaft element (2) and an insertion element (1) according to one of the preceding claims, wherein the insertion element (1) is arranged on the housing (24) and the sleeve (3) such that the sleeve (3) is sealed at least sectionally against the housing (24) and wherein the shaft element (2) is guided through the sleeve (3) and the insertion element (1) into the housing (24). [8] Method (100) for assembling a system (23) according to claim 7 comprising the following steps: - Inserting (120) an insertion element (1) according to one of claims 1 to 6 into a housing (24), - Arranging (130) a sleeve (3) in the housing (24) such that the support collar (9) is arranged between the housing (24) and the sleeve (3) to create a sealing effect, - Inserting (150) a shaft element (2) through the insertion element (1) into the housing (24). [9] Method (100) according to claim 8, characterized by , that the sleeve (3) is pressed into the housing (24). [10] Method (100) according to claim 8 or 9, characterized by , that before inserting (120) the insertion element (1) a sealant is sprayed (110) onto the support collar (9) and / or the first section (6) and / or the second section (7) of the insertion element (1). [11] Method (100) according to any one of the preceding claims 8 to 10, characterized by , that the outer ring (15) is inserted into the housing (24) and pressed in, and wherein the inner ring (16) is only connected (140) to the outer ring (15) after it has been pressed in. [12] Method (200) for replacing a component in a system (23) according to claim 7 comprising the following steps: - Opening (210) the housing (24), in particular the gearbox housing (25), - Removal (220) of components located in the housing (24), - Removal (230) of the shaft element (2), wherein the shaft element (2) is pulled on the side of the sleeve (3), - Removal (240) of the component to be replaced, - Inspection (250) of the insertion element (1) according to one of claims 1 to 6, wherein in the course of the inspection (250) the inner ring (16) is replaced (260), - Inserting (270) the replaced component, - Inserting (280) the shaft element (2) via the sleeve (3) and the insertion element (1) into the housing (24), - Insertion (290) of the removed components, - Closing (300) the housing (24).

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