Axle Assembly with Outboard Bearings for Simplified Packaging

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Solution Overview

Problem

Existing axle assemblies face challenges in easy assembly and packaging of bearings for axle shafts, which complicates the assembly process.

Innovation Solution

The axle assembly design includes a tubular member with end flanges that define bearing bores and mounts for first and second axle bearings, along with a dust shield mount and wheel end cover, allowing for easier assembly by seating the bearings into the tube end connector and abutting the dust shield flange with the wheel end cover flanges, while supporting the axle shaft for rotation relative to the housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If bearings are packaged in the conventional manner within the axle housing, then the axle assembly maintains structural integrity, but the assembly process becomes complex and difficult

Engineering Contradiction:

Improveease of assemblyVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The axle assembly is divided into modular components: the axle housing, the axle shaft assembly with pre-installed bearings, and the wheel end cover. The bearings are segmented into inner and outer races that can be independently positioned and installed, allowing for easier assembly without requiring complex bearing packaging procedures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner and outer bearing races are pre-positioned on the axle shaft and in the axle housing respectively before final assembly. The dust shield is also pre-installed on the axle shaft, creating a prepared state that simplifies the final bearing installation and reduces assembly complexity

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the axle shaft is supported by bearings located within the axle housing, then the structural stability is maintained, but the assembly and disassembly process becomes time-consuming

Engineering Contradiction:

Improveassembly speedVSAvoidassembly time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The wheel end cover is extracted as a separate removable component that encloses the bearing assembly. This allows the entire bearing assembly to be installed and removed as a unit through the wheel end cover, significantly reducing assembly time compared to installing bearings individually within the housing

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The bearing assembly is nested within the wheel end cover, which itself is installed in the axle housing. The inner bearing race is nested on the axle shaft, and the outer bearing race is nested in the axle housing. This nested structure allows for efficient packaging and rapid assembly by installing components in a hierarchical sequence

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS10486467B2Axle assembly with outboard axle bearings

Publication Date: 2019.11.26 AMERICAN AXLE & MANUFACTURING INC

AI summary

An axle assembly having an axle housing, an axle shaft, a plurality of axle shaft bearings and a seal. The axle housing has a tubular member and an end flange that is coupled to the tubular member. The axle shaft bearings and the seal are received in the end flange and are engaged to the axle shaft. The axle shaft bearings support the axle shaft for rotation relative to the axle housing. The seal is sealingly engaged to the end flange and the axle shaft. A method for assembling an axle assembly is also provided.