Driveshaft Plunging Assembly With Outer-Housing Plug Stop
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Solution Overview
Problem
Conventional plunging assemblies in driveshafts face challenges in implementing a stop function for the inner shaft without compromising its strength, and the existing structures are complex and difficult to machine, with issues arising from torsional torque and groove formation.
Innovation Solution
A plunging assembly with an outer housing featuring a bore with outer ball grooves and an inner shaft with paired inner ball grooves, utilizing a plug member inserted into a mounting hole of the outer housing to limit the inner shaft's movement, which includes an O-ring or annular projection for sealing and an elastic damper for shock absorption, and an inclined surface to prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stop rings are provided at both ends of the inner shaft with grooves for seating, then the plunging unit and inner shaft behavior are limited, but the structure becomes complicated and machining becomes difficult
Solution Approach 1:
The stop function is extracted from the inner shaft and relocated to the outer housing. The plug member is inserted into a mounting hole formed in the bore of the outer housing, separating the stopping function from the inner shaft structure. This eliminates the need for grooves on the inner shaft and simplifies its design while maintaining the limitation function.
Solution Approach 2:
A plug member is introduced as an intermediary component to provide the stop function. The plug member is inserted into a mounting hole in the outer housing and provides a stopping surface for the inner shaft, acting as a mediator between the outer housing and inner shaft to limit movement without requiring complex grooves on the inner shaft.
2Reliability
If a groove is formed to mount a stop ring on the proximal side of the inner shaft, then the stop function is provided, but the inner shaft can be broken even at a small torsional torque
Solution Approach 1:
The stop function is extracted from the inner shaft and relocated to the outer housing. By forming the mounting hole in the bore of the outer housing rather than cutting a groove in the inner shaft, the inner shaft's structural integrity is preserved and it can withstand torsional torque without weakening.
Solution Approach 2:
The stopping function is segmented from the inner shaft and placed in a separate location (outer housing). The plug member mounted in the outer housing provides the stop function independently, allowing the inner shaft to remain continuous and strong without interruptions or grooves that would create stress concentration points.
3Reliability
If conventional stop rings are used to limit inner shaft movement, then the plunging assembly structure is defined, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The stop function is extracted from the inner shaft and implemented in the outer housing. The mounting hole is formed in the bore of the outer housing, which can be done during the housing manufacturing process itself, eliminating the need for separate groove machining operations on the inner shaft and reducing overall manufacturing complexity and time.
Solution Approach 2:
The mounting hole formation is merged with the outer housing manufacturing process. Instead of separately machining grooves on the inner shaft and assembling stop rings, the plug member is directly inserted into a hole formed in the outer housing, combining multiple functions into a single manufacturing step and improving productivity.
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 effectively limits the inner shaft's movement without reducing its strength, prevents grease leakage, and reduces impact during collisions, while maintaining the assembly's structural integrity and operational efficiency.
Implementation Method 1
an elastic damper for shock absorption
Implementation Method 2
an O-ring or annular projection for sealing
Data Source
AI summary
A plunging assembly of a driveshaft includes: an outer housing having a bore having a plurality of outer ball grooves extending in a longitudinal direction; an inner shaft being disposed to be able to undergo relative movement in the longitudinal direction in the bore of the outer housing and having a plurality of inner ball grooves that are paired respectively with the outer ball grooves to form a plurality of ball tracks; a plunging unit connecting the outer housing and the inner shaft to allow a plunging motion and a rotational power transmission between the outer housing and the inner shaft; and a stopper that is provided in the bore of the outer housing to limit relative movement of the inner housing and the inner shaft in a direction in which the inner shaft is inserted into the bore. The outer housing has a mounting hole communicating with the bore, and the stopper is a plug member that is inserted into the mounting hole in a state that a frontal end portion thereof is exposed to the bore.