Torsion-Elastic Cardan Joint With Direct-Welded Disk Flange
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Solution Overview
Problem
Existing flange-pipe connections for torsion-elastic cardan joints are costly, heavy, and require significant effort to produce and stock due to the need for custom-adapted flanges based on pipe dimensions, which is a disadvantage in vehicle construction.
Innovation Solution
A torsion-elastic cardan joint with a disk-shaped flange part that is directly connected to the shaft without an axial welding attachment, using friction welding and incorporating reinforcing features like beads and bulges for increased stiffness, and produced from sheet-metal semi-finished products for cost-effectiveness and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If forged flange parts with welding attachments are used for each pipe attachment, then torque-proof connection is achieved, but weight increases and manufacturing costs rise
Solution Approach 1:
The patent changes the material parameters and structural parameters of the flange by using sheet metal instead of forged material, and by eliminating the welding attachment. The flange is designed with optimized thickness and diameter parameters that provide sufficient torque transmission capability while significantly reducing weight compared to traditional forged flanges with welding attachments
Solution Approach 2:
The patent extracts and removes the welding attachment component from the flange structure. By taking out the tubular welding attachment that was previously integrated into forged flanges, the design achieves weight reduction and simplifies manufacturing while maintaining torque-proof connection through direct sheet metal construction
2Adaptability or versatility
If custom-adapted flanges are produced for each pipe dimension, then compatibility with different pipes is achieved, but manufacturing effort and stocking requirements increase
Solution Approach 1:
The patent creates a universal flange design based on sheet metal that can accommodate multiple pipe dimensions and configurations. The standardized sheet metal flange with optimized geometric parameters serves multiple functions across different pipe sizes, eliminating the need for custom-forged flanges for each specific pipe dimension and significantly reducing manufacturing effort and inventory requirements
3Strength
If forged flange parts are used, then structural strength is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive forged flange parts with more economical sheet metal flanges. The sheet metal construction provides sufficient strength for the application while being significantly cheaper to manufacture, though it may have different lifecycle characteristics compared to forged parts
Solution Approach 2:
The patent changes the manufacturing parameters and material form from forged to sheet metal, which fundamentally alters the cost structure. The sheet metal flange with optimized thickness and diameter parameters achieves the required strength at lower manufacturing cost compared to traditional forged flanges
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
The solution results in a lightweight, cost-effective torsion-elastic cardan joint with reduced manufacturing costs and improved stiffness, enabling efficient torque transmission while minimizing the need for custom flange production and weight.
Implementation Method 1
The shaft is immediately coaxially connected directly to this disk-shaped flange part in a torque-proof manner
Data Source
AI summary
A torsion-elastic cardan joint for connecting a shaft with a second component that is not continuously coaxial during torque transmission, which comprises a torsion-elastic power transmission system, a flange connected to this in a torque-proof manner, and a second flange connected to this in a torque-proof manner on the opposite end face of the torsion-elastic power transmission system. The shaft-side flange is coaxially connected to the shaft and the second flange is coaxially connected to the second component in a torque-proof manner. The shaft-side flange consists of a dimensionally stable disk-shaped flange part (1, 10, 12). The shaft is directly connected to this disk-shaped flange part (1, 10, 12) in a torque-proof manner, for example, via friction welding. As a result, there is no need to adapt the shaft-side flange to the dimensions of the shaft.