Axle Assembly Deformation for Axial Securing
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Solution Overview
Problem
Existing vehicle axle or shaft assemblies require costly and time-consuming securing methods using additional elements, leading to increased parts, weight, and production costs, as well as complex machining processes.
Innovation Solution
The assembly secures the first component as an axle or shaft to the second component using deformations on the same axial side in both the first and second directions, eliminating the need for additional securing elements and simplifying the production process by using a single actuator for deformation, such as a pneumatic cylinder, and distributing deformations uniformly to avoid load peaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional securing elements (such as securing rings, nuts, or stop surfaces) are used to secure the axle or shaft axially, then the axial securing reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the need for separate securing elements (securing rings, nuts, stop surfaces) by integrating the axial securing function directly into the deformation structure. The deformation itself creates the securing effect through material flow and interlocking, removing unnecessary components while maintaining securing reliability.
Solution Approach 2:
The invention merges the function of axial securing with the deformation process. Instead of using separate securing elements, the deformation structure itself performs both the connection and the axial securing functions through integrated material flow patterns that create interlocking between components.
2Reliability
If additional securing elements and complex machining processes are used, then the axial securing is more reliable, but the production time and manufacturing cost increase
Solution Approach 1:
The invention performs preliminary action by creating the deformation structure that inherently provides axial securing during the forming process itself. The material flow is pre-designed to create interlocking features that provide axial securing without requiring subsequent machining or installation of separate securing elements, thus accelerating production.
Solution Approach 2:
The deformation structure serves itself by creating the axial securing features through its own material flow and deformation pattern. The material flows in a way that automatically creates interlocking structures during the forming process, eliminating the need for additional securing elements and complex machining operations.
3Reliability
If additional securing elements are used, then the axial securing is more reliable, but the weight of the assembly increases
Solution Approach 1:
The invention extracts and removes the weight of separate securing elements (securing rings, nuts, washers) by integrating the axial securing function into the deformation structure itself. The deformation creates sufficient mechanical interlocking without requiring additional material, thus reducing overall assembly weight while maintaining securing reliability.
4Reliability
If deformations are applied on both axial sides, then the axial securing reliability is improved, but the device complexity and production cost increase
Solution Approach 1:
The invention applies asymmetric deformation configuration where the deformation is applied predominantly on one axial side rather than symmetrically on both sides. The material flow is designed to create sufficient interlocking and axial securing through asymmetric deformation patterns, reducing device complexity while maintaining securing reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for a cost-effective and rapid production of vehicle assemblies by eliminating the need for additional securing elements and simplifying machining, resulting in a more secure and efficient axial securing process.
Implementation Method 1
at least one of the components has, on one side, in particular an axial side, at least one first deformation by means of which the first component is secured to the second component in a first direction coinciding with the axial direction of the first component
Data Source
AI summary
An assembly of a first component designed as an axle or a shaft on a second component, is provided, in particular for a vehicle. The first component is secured to the second component at least in the axial direction of the first component. At least one of the components has at least one first deformation on one side, the deformation being used to secure the first component on the second component in a first direction which coincides with the axial direction. At least one of the components has at least one second deformation on the same side, the second deformation being used to secure the first component on the second component in a second direction which coincides with the axial direction and is opposite the first direction.