Composite Drive Shaft Diaphragm Structure for High Torque and Low Weight
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Solution Overview
Problem
Drive shafts in modern mechanical systems face challenges in transmitting high torque at high speeds while minimizing weight and maintaining structural integrity under varying loads, as existing metallic and composite materials struggle to balance torsional stiffness with flexural and axial load resistance.
Innovation Solution
A drive shaft formed from fiber-reinforced polymer matrix composites, featuring separate diaphragm members with undulations and a connecting tubular portion, where the diaphragms and tube are made from the same composite materials and connected through mechanical joints, allowing for enhanced torsional stiffness and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for drive shafts, then torsional stiffness and structural integrity are improved, but weight increases
Solution Approach 1:
The drive shaft employs fiber-reinforced polymer matrix composite materials for both the tubular portion and diaphragm members. This composite construction provides high strength-to-weight ratio, delivering the required torsional stiffness and structural integrity while significantly reducing weight compared to traditional metallic materials.
2Weight of moving object
If composite materials are used for drive shafts, then weight is reduced, but structural integrity and torsional stiffness deteriorate
Solution Approach 1:
The patent utilizes fiber-reinforced polymer matrix composites with optimized fiber orientation and distribution to achieve high structural integrity. The composite material selection and lamination design ensure adequate torsional stiffness and load-bearing capacity while maintaining weight reduction benefits.
Solution Approach 2:
The drive shaft is divided into distinct components (tubular portion and diaphragm members) that can be separately manufactured and then assembled. This segmentation allows for optimized design of each component while using the same composite material system, ensuring both weight reduction and structural integrity through precise component-level optimization.
3Ease of manufacture
If diaphragms and tube are formed as one integral unit, then manufacturing complexity is reduced, but design flexibility deteriorates
Solution Approach 1:
The drive shaft is constructed from separate diaphragm members and a tubular portion that are manufactured independently and then assembled through mechanical connection at joints. This segmentation enables independent optimization of each component's design and manufacturing process while maintaining overall system performance, providing both manufacturing efficiency and design flexibility.
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 configuration achieves weight reduction, simplifies manufacturing and assembly, and provides greater design flexibility while maintaining structural integrity and torsional stiffness, effectively addressing the limitations of prior drive shaft technologies.
Implementation Method 1
The diaphragms have an undulation to allow some flexing
Implementation Method 2
The first and second diaphragm members and the tubular portion are formed of fiber-reinforced polymer matrix composites
Data Source
AI summary
A drive shaft is for selectively connecting a drive input to an output. The drive shaft has a tubular portion, a first diaphragm member, and a second diaphragm member displaced axially along the shaft from the first diaphragm member. The first and second diaphragm members each are formed with two axial ends. At least one undulation extends radially of the ends. The tubular portion connects the first and second diaphragm members. The first and second diaphragm members and the tubular portion are formed of fiber-reinforced polymer matrix composites. The first and second diaphragm members are connected to first and second axial ends of the tubular portion through a mechanical connection at joints. There is also a method of forming a drive shaft.