Composite Driveshaft Welded Joint Assembly for Reliable Torque Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Designing composite driveshafts that connect to metallic components is challenging due to high operating temperatures, rotational speeds, torsional loading, and size constraints, limiting their implementation in vehicles and making it difficult for manufacturers to produce and assemble joints that maintain connection integrity while being manufacturable and economical.
Innovation Solution
A modular joint-to-tube adapter system with welded joints and adhesive bonding, allowing composite tubes to be used as torque-transferring components with fully metallic joints at the ends, enabling versatile fabrication and repair of composite driveshafts without fabricating the tubes themselves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite tubes are used to reduce weight, then weight reduction is achieved, but connection integrity with metallic components deteriorates due to high operating temperatures, rotational speeds, and torsional loading
Solution Approach 1:
The patent employs a hybrid composite structure combining composite materials (for the tube providing weight reduction) with metallic materials (for the joints providing high-temperature and high-load strength). This allows the driveshaft to achieve weight reduction while maintaining connection integrity through the metallic joint components that can withstand the harsh operating conditions.
Solution Approach 2:
The patent merges composite tube sections with metallic joint components to create a hybrid driveshaft system. The metallic joints are integrated with the composite tubes through bonding and mechanical connection, combining the advantages of both material types: weight reduction from composite materials and reliability under extreme conditions from metallic materials.
2Adaptability or versatility
If custom composite driveshafts are manufactured, then application versatility is improved, but manufacturing complexity increases due to specialized facilities and assembly processes
Solution Approach 1:
The patent divides the driveshaft into modular segments: standard composite tube sections and separate joint assemblies. The tubes can be produced using conventional composite manufacturing processes, while joints are manufactured separately as standardized components. This segmentation allows different segments to be produced in different facilities and then assembled, reducing overall manufacturing complexity while maintaining versatility.
Solution Approach 2:
The patent designs universal joint components that can interface with various composite tube configurations and driveline applications. The standardized joint assemblies can be adapted to different tube diameters, lengths, and configurations, allowing a single joint design to serve multiple applications and reducing the need for custom-manufactured components for each specific application.
3Force
If metallic joints are added to composite tubes, then torque transfer capability is improved, but cost increases due to additional materials and assembly processes
Solution Approach 1:
The patent introduces bonding agents as intermediary materials between the metallic joints and composite tubes. These bonding agents facilitate the connection, distributing loads and enabling effective torque transfer. By using bonding agents, the design achieves improved torque capability while avoiding the need for more complex and expensive mechanical fastening systems, thus controlling manufacturing costs.
4Strength
If bonded connections are used between metallic joints and composite tubes, then connection strength is improved, but manufacturing precision requirements increase due to bonding process control
Solution Approach 1:
The patent incorporates preliminary preparation features in the joint and tube designs, such as pre-formed bonding surfaces, alignment features, and tolerance-built interfaces. These preliminary actions ensure that when the bonding process occurs, the components are already positioned and prepared correctly, reducing the precision requirements during the actual bonding operation and simplifying manufacturing control.
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 solution provides a strong, versatile, and cost-effective way to integrate composite driveshafts into vehicles, enabling custom and aftermarket implementations by ensuring reliable torque transfer and bonding strength up to high torque capacities, facilitating their use in various automotive applications.
Implementation Method 1
A welded joint system may be arranged at one or both of the tube input and output ends. Each welded joint system may include a sleeve and joint assembly that are welded to each other.
Implementation Method 2
The sleeve is bonded to the respective one of the tube input and output ends after welding.
Data Source
AI summary
A composite vehicle driveshaft is provided with a composite tube and a welded joint system(s) at one or both ends of the composite tube for connecting the composite vehicle driveshaft to driveline components. Each welded joint system may include a sleeve that is bonded to an end of the composite tube and a joint assembly that is welded to the sleeve.