Biased Plunge Pin Assembly for Tool-Free Axle Decoupling
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Solution Overview
Problem
The removal and replacement of drive axles in all-terrain vehicles (ATVs) require specialized tools due to the use of spring clips, making the process difficult and tool-dependent.
Innovation Solution
A plunge pin assembly with a biased clip that can be actuated by hand, allowing for decoupling of the driven system from the driving system without tools, utilizing a transfer pin and tapered contours to contract and expand, enabling tool-free operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring clip is used to retain the driven system to the driving system, then secure coupling during operation is achieved, but removal and replacement requires specialized tools and is difficult to execute
Solution Approach 1:
The plunge pin assembly enables the system to perform its own retention and release functions without external tools. The biased clip automatically engages with the driving system to secure the driven system during operation, and can be manually actuated by applying axial force to release the retention, allowing the system to serve both securing and releasing functions through its inherent mechanical design
Solution Approach 2:
The retention mechanism transitions from a static spring clip to a dynamic system where the clip can be actively controlled. The biased clip remains engaged during normal operation but can be deliberately disengaged by applying axial force to the plunge pin, creating a controllable transition between retained and released states that enables both secure coupling and easy removal
2Reliability
If a spring clip is used to retain the driven system, then secure coupling is achieved, but the process becomes tool-dependent and complex
Solution Approach 1:
The plunge pin assembly merges the retention function and release function into a single integrated mechanism. The biased clip and plunge pin work together as one unit where the same assembly that provides secure coupling during operation also enables tool-free removal through manual actuation, eliminating the need for separate specialized tools
Solution Approach 2:
The plunge pin assembly serves multiple functions: it provides secure retention during operation through the biased clip engagement, enables tool-free removal through manual axial actuation, and allows for repeated coupling and decoupling cycles. This multi-functional design eliminates tool dependency while maintaining reliable coupling
3Ease of operation
If the clip is made circumferentially contractable and expandable, then tool-free actuation is enabled, but the mechanism becomes more complex
Solution Approach 1:
The clip is designed with circumferential curvature that allows it to contract and expand radially. This curved geometry enables the clip to be compressed radially inward for engagement and expanded radially outward for disengagement, providing tool-free actuation through simple axial motion of the plunge pin that converts to radial movement of the clip
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
Enables easy and tool-free removal and replacement of drive axles, improving maintenance accessibility and reducing the need for specialized tools, while maintaining secure coupling during vehicle operation.
Implementation Method 1
a plunge pin biased toward the first end of the housing
Implementation Method 2
A transfer pin cooperates with tapered and recessed contours of the plunge pin to permit the aforementioned actuation of the clip
Data Source
AI summary
A vehicle, such as off road vehicle, includes a plunge pin assembly located in a flexible joint, which maybe actuated without tools to decouple and thus remove a driven system from a driving system. The plunge pin assembly includes a plunge pin biased to an installed position such that a clip of the plunge pin assembly retains the driven system to the driving system during operation of a vehicle. The clip (e.g., circlip, snap ring, coil spring or crest wave spring) is circumferentially contractable and expandable. A transfer element cooperates with tapered and recessed contours of the plunge pin to permit the aforementioned actuation of the clip. Movement of the transfer pin along with contraction of the clip allows the driven system to be decoupled from the driving system. The plunge pin may include a head portion positioned at a desired distance from a drive axle of the driven system.