Counter Track Joint With Split-Finished Ball Tracks for Large Angles

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Solution Overview

Problem

Existing constant velocity joints are costly and have limited efficiency and service life, particularly when designed for large articulation angles.

Innovation Solution

A counter track joint design with one ball track group hardened and hard-machined, and the other group soft-finished and hardened, allowing for efficient guiding and supporting functions while reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If both ball track groups are hard-machined after hardening, then manufacturing precision and guiding function are improved, but manufacturing cost and production time increase significantly

Engineering Contradiction:

Improveball track guiding precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The ball track groups are segmented into two categories with different machining requirements. The first ball track group undergoes hard-machining after hardening to achieve high precision, while the second ball track group uses soft-finishing before hardening to reduce costs. This segmentation allows optimization of manufacturing precision where needed while controlling overall production costs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different quality levels are applied to different ball track groups based on their functional requirements. The first ball track group receives higher quality treatment (hard-machining after hardening) for critical guiding functions, while the second group uses cost-effective soft-finishing. This local quality differentiation resolves the contradiction between precision and cost.

Inventive Principle:

Principle #3Local quality

2Productivity

If both ball track groups are soft-finished before hardening, then manufacturing cost is reduced, but guiding precision and supporting function deteriorate

Engineering Contradiction:

Improvemanufacturing costVSAvoidball track guiding precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The ball track groups are divided into two categories: the first group uses soft-finishing before hardening for cost efficiency, while the second group undergoes hard-machining after hardening for high precision. This segmentation ensures that cost reduction does not compromise the guiding precision required for proper joint operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different finishing qualities are applied locally to different ball track groups. The soft-finished first group provides adequate function at lower cost, while the hard-machined second group ensures high precision where needed. This local differentiation maintains overall system performance while reducing total manufacturing cost.

Inventive Principle:

Principle #3Local quality

3Reliability

If all components are hardened, then service life and wear resistance are improved, but manufacturing complexity and production time increase

Engineering Contradiction:

Improveservice lifeVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Hardening is applied selectively to specific components and regions rather than uniformly to all parts. The ball track groups have different hardening treatments based on their functional requirements, and the support face is hardened to enhance durability. This local quality approach improves service life where critical while avoiding unnecessary hardening elsewhere, thus reducing manufacturing complexity.

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If the joint is designed for large articulation angles, then versatility and application range are improved, but efficiency and service life deteriorate

Engineering Contradiction:

Improvearticulation angle rangeVSAvoidjoint efficiency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The ball tracks are designed with varying degrees of curvature and widening in different regions to accommodate large articulation angles while maintaining efficiency. The first and second ball track groups have different geometric characteristics optimized for their specific functional requirements, allowing the joint to achieve both large articulation range and high efficiency simultaneously.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The ball track geometry is dynamically adapted through varying curvature and widening patterns that respond to different articulation angles. The tracks are designed to guide balls effectively across a range of motion, maintaining proper contact and reducing wear even at large articulation angles, thus preserving joint efficiency and service life.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12523260B2Counter track joint

Publication Date: 2026.01.13 GKN DRIVELINE INT GMBH

AI summary

A counter track joint comprises an outer joint part, an inner joint part, first pairs of tracks widening towards the opening side of the outer joint part when the counter track joint is aligned, and second pairs of tracks widening towards the connecting side of the outer joint part when the counter track joint is aligned; a ball in each of the first and second pairs of tracks; a ball cage having circumferentially distributed cage windows each receiving one of the balls, wherein one of the outer ball track group and the inner ball track group is hardened and hard machined, and the other of the outer ball track group and the inner ball track group is soft finished and subsequently hardened. A method of manufacturing a counter track joint is provided.