Constant Velocity Joint Outer Race Magnetic Pulse Welding
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Solution Overview
Problem
Existing constant velocity joint designs are inadequate for securely connecting a tube, such as a drive shaft tube, due to their thin nature and exposed elastomeric boots, which are prone to damage, and they require additional hardware that increases weight and cost.
Innovation Solution
A constant velocity joint assembly with an outer race that is magnetically pulse welded to a shaft, using an inductor to create a strong magnetic field for welding, and a flexible boot protected by the outer race to prevent damage and reduce hardware requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If prior art joint designs use thin disk structures, then the joint can be lightweight, but they cannot provide sufficient welding surface for secure tube connection
Solution Approach 1:
The joint structure transitions from a thin two-dimensional disk to a three-dimensional construction with an outer race having substantial thickness. This dimensional change provides adequate welding surface area while maintaining overall compactness through the nested configuration of the outer race containing the joint components.
Solution Approach 2:
The joint components (inner race, balls, cage) are nested within the outer race, allowing the outer race to serve as both a structural element providing welding surface and a containing structure. This nesting eliminates the need for separate thick mounting structures, achieving strong connections without excessive weight.
2Reliability
If prior art designs use exposed elastomeric boots, then the boot can be simple in structure, but it becomes vulnerable to damage from environmental exposure
Solution Approach 1:
The outer race is designed to extend and cover the elastomeric boot, merging the protective function into the existing structural component rather than adding a separate protective element. This integration protects the boot from environmental damage while avoiding additional complexity.
Solution Approach 2:
The elastomeric boot itself serves as a flexible protective shell, and the outer race provides an additional rigid protective layer. This layered approach uses flexible and rigid materials working together to protect the boot without complex mechanical protective structures.
3Strength
If prior art joints use bolts and flanges for connection, then the joint can be securely connected to tubes, but the weight and cost increase
Solution Approach 1:
The mechanical connection system of bolts and flanges is replaced with direct magnetic pulse welding. The outer race provides a sufficient welding surface for direct attachment to the drive shaft tube, eliminating the need for separate mechanical fasteners and reducing both weight and assembly complexity.
Solution Approach 2:
The outer race serves multiple functions: it contains the joint components, provides structural support, and serves as the welding surface for tube connection. This multi-functionality eliminates the need for separate flanges or mounting structures, reducing hardware weight and cost.
4Strength
If prior art joints require additional connection hardware, then the joint can be securely assembled, but the appearance becomes less clean and cost increases
Solution Approach 1:
The connection function is merged into the outer race itself, which serves as both a structural component and a mounting surface. This integration eliminates the need for separate flanges, bolts, and other connection hardware, resulting in a cleaner appearance and fewer parts.
Solution Approach 2:
The unnecessary connection hardware (flanges, bolts, washers) is extracted from the design, leaving only the essential components needed for joint operation and connection. This simplification maintains assembly security through direct welding while reducing component count and improving aesthetics.
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 provides a secure and lightweight connection with reduced risk of boot damage, enabling efficient power transmission and weight savings while maintaining a clean design and improved durability.
Implementation Method 1
An inductor may be located axially relative to the outer race and the tube where it is then energized to magnetically pulse weld the two together.
Data Source
AI summary
A constant velocity joint assembly and a method of securing a shaft to the assembly are described. The assembly may have an outer race with a first portion having a plurality of grooves and a second portion that extends from the first portion and is substantially parallel to the shaft. The method of securing the shaft to the assembly includes the step of magnetically pulse welding the shaft to the outer race.