CV Joint Ball Cage Contours for Easier Axial Assembly Alignment
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Solution Overview
Problem
The existing configuration of constant velocity joints, particularly 8-ball fixed CV joints, faces challenges in establishing axial positioning of joint centers during assembly due to the lack of structural constraints, making alignment difficult and cumbersome without additional fixtures.
Innovation Solution
Incorporating a combination of cylindrical and spherical contours on the inner and outer surfaces of the outer race, ball cage, and inner race, allowing for axial insertion and rotation while maintaining alignment of joint centers, facilitating easier assembly and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cylindrical surfaces are used to provide clearance for ease of axial insertion, then ease of assembly is improved, but the ability to establish axial positioning of joint centers deteriorates
Solution Approach 1:
The inner surface of the outer race is segmented into two distinct portions: a first portion with a cylindrical contour and a second portion with a spherical contour. The cylindrical portion provides clearance for ease of axial insertion, while the spherical portion establishes precise axial positioning of the joint centers. This segmentation allows both contradictory requirements to be satisfied simultaneously.
Solution Approach 2:
Different regions of the inner surface are given different geometric qualities - the first portion has a cylindrical contour that provides clearance and facilitates insertion, while the second portion has a spherical contour that provides precise positioning. This local differentiation of surface properties resolves the contradiction between ease of assembly and positioning precision.
2Reliability
If only spherical contours are used to maintain structural integrity, then reliability is improved, but ease of axial assembly deteriorates
Solution Approach 1:
The surface geometry is segmented into cylindrical and spherical portions, where the cylindrical portion facilitates easy axial assembly by providing clearance, and the spherical portion maintains structural integrity and establishes precise positioning. This segmentation resolves the contradiction between ease of assembly and structural reliability.
3Manufacturing precision
If additional fixtures are used to align joint centers, then manufacturing precision is improved, but device complexity deteriorates
Solution Approach 1:
The spherical contour on the inner surface of the outer race enables the ball cage to self-align and establish precise axial positioning of joint centers during assembly without requiring external fixtures or complex alignment tools. The geometry itself provides the positioning function, eliminating the need for additional alignment devices.
Solution Approach 2:
The spherical contour acts as an intermediary geometric feature that mediates between the cylindrical clearance portion and the ball cage, automatically establishing precise axial positioning of joint centers during assembly without requiring external fixtures.
Data Source
AI summary
A constant velocity joint assembly includes an outer race having a first bore defined by an inner surface of the outer race. A ball cage has an outer surface and a second bore defined by an inner surface of the ball cage. The ball cage is axially received in the first bore of the outer race. At least one of the inner surface of the outer race or the inner surface the ball cage includes a first portion having a cylindrical contour and a second portion having a spherical contour.