Plunge Constant Velocity Joint Piston Seal Design
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Solution Overview
Problem
Constant velocity joints require additional lubricant due to extra plunge capability needed for installation, increasing costs and potential failure modes during operation.
Innovation Solution
An outer race assembly with a piston that is selectively movable along tracks in the outer race, sealed by a seal that abuts the outer race, allowing reduced lubricant usage while maintaining adequate plunge capability for installation and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If extra plunge capability is designed into the joint to facilitate installation between vehicle components, then ease of installation is improved, but the amount of lubricant required increases
Solution Approach 1:
The joint is divided into two functional zones: a sealed inner chamber containing the constant velocity mechanism with minimal lubricant, and an unsealed outer plunge zone that accommodates installation movement. The seal member creates this segmentation, allowing the inner chamber to maintain only the lubricant necessary for CV joint operation while the outer zone provides additional plunge capability without requiring proportional lubricant increase.
Solution Approach 2:
The seal member extracts and isolates the lubricant containment function to a specific location, separating the lubricant requirement from the total plunge capability. This allows the joint to have plunge capability extending beyond the sealed chamber without requiring the entire extended volume to be filled with lubricant, thus reducing total lubricant quantity while maintaining installation ease.
2Adaptability or versatility
If extra plunge capability is designed into the joint beyond ordinary operation needs, then adaptability for installation is improved, but costs increase due to additional lubricant
Solution Approach 1:
The joint structure is segmented into a sealed operational chamber and an unsealed plunge extension zone. The seal member defines the boundary between these zones, allowing the plunge capability to extend into the unsealed zone without requiring lubricant filling throughout the entire extension, thus maintaining adaptability while reducing lubricant quantity and associated costs.
Solution Approach 2:
Different zones of the joint have different sealing and lubricant requirements. The inner chamber has full sealing and minimal lubricant for CV operation, while the outer plunge zone is unsealed and does not require additional lubricant. This local differentiation allows high plunge capability with low total lubricant quantity.
3Reliability
If the joint is sealed to retain grease and keep contaminants out, then reliability is improved, but the amount of lubricant required increases to fill the sealed volume
Solution Approach 1:
The seal member creates a segmented structure with a compact sealed inner chamber that contains only the lubricant necessary for constant velocity joint operation. The sealed volume is minimized to the essential operational space, while the additional plunge capability exists in an unsealed outer zone, thus maintaining reliability through sealing while minimizing lubricant quantity.
Solution Approach 2:
The seal member is positioned to seal the inner chamber while allowing the outer race to plunge dynamically beyond the sealed zone during installation. This dynamic configuration maintains reliable sealing for the essential operational volume while permitting unsealed extension for installation, optimizing both reliability and lubricant efficiency.
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
The solution reduces the amount of lubricant needed within the joint, minimizing costs and potential failure modes while ensuring proper operation and installation of the constant velocity joint.
Implementation Method 1
a seal disposed about the piston and abutting the outer race about substantially an entire perimeter of the piston. The seal thereby generally seals an interface between the piston and the outer race.
Implementation Method 2
A piston is secured to a rear end of a shaft beyond torque transmitting rollers and is provided with radially outwardly extending projections having side walls slidably engaging the walls of the grooves of the outer member.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
An outer race assembly for a constant velocity joint is disclosed. The outer race assembly may include an outer race defining a plurality of tracks and a piston selectively moveable along the tracks of the outer race. The outer race assembly may further include a seal disposed about the piston and abutting the outer race about substantially an entire perimeter of the piston. The seal thereby generally seals an interface between the piston and the outer race.