Constant Velocity Joint Housing Connection for Compact EV Drivelines
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Solution Overview
Problem
Contemporary constant velocity joints are physically large and heavy, making them difficult to install and inefficient for use in electric vehicles where a differential may not be necessary, as each wheel can be driven by a separate motor.
Innovation Solution
A constant velocity joint design featuring a splined shaft that couples with a planetary carrier, using a spline to attach the outer race, allowing for a smaller size and lighter weight while maintaining torque handling capabilities, and incorporating an O-ring gland and clip interface for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional constant velocity joints are used to connect differential to half shaft, then torque transmission is achieved, but the joint becomes physically large and heavy, making installation difficult
Solution Approach 1:
The constant velocity joint is divided into separate modular components: a first constant velocity joint for the drive shaft and a second constant velocity joint for the half shaft. This segmentation allows each joint to be optimized independently and installed separately, reducing overall complexity and improving ease of installation while maintaining torque transmission capability.
Solution Approach 2:
The invention extracts and eliminates the differential component from the traditional drivetrain configuration. By using independent constant velocity joints at each wheel, the differential is removed entirely, significantly reducing the weight and complexity of the constant velocity joint system while still enabling torque distribution to multiple wheels.
2Adaptability or versatility
If conventional constant velocity joints with differential are used, then torque distribution is achieved, but the overall system size increases
Solution Approach 1:
The differential is extracted and removed from the system. Instead of using a centralized differential to distribute torque, the invention employs independent constant velocity joints at each wheel that can be directly connected to electric motors, significantly reducing system volume while maintaining adaptability to electric vehicle architectures.
Solution Approach 2:
The drivetrain is segmented into independent wheel-end units, each with its own constant velocity joint. This modular segmentation eliminates the need for a large centralized differential housing and allows for compact integration with electric motors, reducing overall system volume while improving adaptability to various electric vehicle layouts.
3Strength
If traditional constant velocity joint design is used, then torque handling capability is maintained, but the joint becomes physically heavy and bulky
Solution Approach 1:
The constant velocity joint components utilize composite construction methods, combining different materials to achieve optimal strength-to-weight ratio. The joints are designed with reinforced structures that maintain torque handling capability while using lighter materials compared to traditional heavy-duty constant velocity joints, thereby reducing weight without compromising strength.
Solution Approach 2:
By segmenting the drivetrain into separate constant velocity joints at each wheel rather than using a single large joint with differential, each joint can be optimized for its specific torque requirements. This allows for lighter-weight construction in each individual joint while collectively handling the same total torque load, reducing overall system weight.
Data Source
AI summary
A constant velocity joint for use in a vehicle and a method of mounting a constant velocity joint including a splined shaft. The constant velocity joint also includes an O-ring gland, an inner race, an outer race, rolling elements, and a boot. The splined shaft of the constant velocity joint transmits torque from a splined hub of a second rotating element.