Constant Velocity Joint Quick Connector Assembly
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Solution Overview
Problem
Existing constant velocity joints in propshaft assemblies face challenges with non-constant rotational velocity transmission, complex assembly processes, contamination risks, and vibration issues due to the use of seal boots and multi-bolt adapters, which require cumbersome threaded mechanisms and hinder efficient assembly and balancing.
Innovation Solution
A shaft assembly with a constant velocity joint featuring an outer and inner race, bearing balls, and a boot assembly that allows for direct engagement and sealing, enabling pre-assembled and lash-free operation with a coupling portion that extends for easy installation, reducing assembly labor and contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-bolt adapter is employed between the constant velocity joint and the driveline component, then the connection is secure, but the assembly labor increases and significant mass is added
Solution Approach 1:
The patent merges the adapter function directly into the constant velocity joint by providing a coupling portion that extends from the boot assembly and engages directly with the driveline component shaft. This eliminates the separate multi-bolt adapter component while maintaining secure connection through direct engagement features.
2Device complexity
If the member of the driveline component is installed through the seal boot to engage directly to the inner race, then the adapter is eliminated, but the assembly technician must align the member and inner race in a blind manner which is difficult and time consuming
Solution Approach 1:
The coupling portion is pre-assembled to the constant velocity joint outer race with the boot assembly already in place, creating a pre-integrated unit. This preliminary assembly allows the coupling portion to be positioned and aligned externally before final engagement, eliminating the need for blind alignment during installation.
3Reliability
If the seal boot is clamped to the member of the driveline component after installation, then sealing is achieved, but additional work must be performed on the vehicle assembly line
Solution Approach 1:
The boot assembly is merged with the coupling portion and outer race as an integrated pre-assembled unit. The boot is permanently attached to the outer race during manufacturing, eliminating the need for separate clamping operations on the assembly line while maintaining sealing integrity through the integrated design.
4Object-affected harmful factors
If the constant velocity joint interior is closed before the driveline component member is engaged, then contamination is prevented, but the joint cannot be balanced as a unit and a tooling component must be used
Solution Approach 1:
The coupling portion is pre-assembled to the outer race with the boot assembly in place, creating a sealed but balanced unit before final driveline component installation. This preliminary integration allows the constant velocity joint to be rotationally balanced as a complete unit while maintaining interior sealing, eliminating the need for tooling components during balancing.
5Manufacturing precision
If a threaded mechanism is used to assemble or disassemble the member from the inner race, then an interference fit can be achieved, but the mechanism is cumbersome to operate requiring open end wrenches
Solution Approach 1:
The threaded mechanism is extracted and replaced with a direct engagement design where the coupling portion engages the driveline component shaft through interference fit and geometric features. This eliminates the need for nuts, bolts, and wrenches while maintaining precise interference fit through direct mechanical engagement.
Data Source
AI summary
A shaft assembly that includes a propshaft member and a constant velocity joint. The constant velocity joint has an outer race, which is coupled for rotation with the propshaft member, an inner race, a plurality of bearing balls disposed between the outer and inner races to transmit rotary power therebetween, a shaft member coupled for rotation with the inner race, and a boot assembly that is sealingly engaged to the outer race and the shaft member. The shaft member defines a coupling portion that extends from the boot assembly. A method for coupling a shaft member to a driveline component is also provided.