Synchronizing Joint Embossing for Roller Retention in Bent-Axis Units
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Solution Overview
Problem
Existing universal joints, such as cardan joints, are unable to compensate for distance variations between driveshaft and cylinder block, leading to complex assembly processes that contaminate hydraulic fluid and introduce dirt into hydrostatic bent axis axial piston units.
Innovation Solution
A synchronizing joint with embossed areas on roller carriers secures rollers in place, preventing them from slipping off during assembly and operation, using a laser application to enhance the carrier diameter locally and ensure secure mounting without additional material or mechanical processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing universal joints (cardan joints) are used, then the structure is simple and well-known, but they are unable to compensate for distance variations between driveshaft and cylinder block, leading to complex assembly processes
Solution Approach 1:
The synchronizing joint incorporates rollers that can pivot and adjust their position dynamically to compensate for distance variations between the driveshaft and cylinder block. The roller carriers are designed to move angularly, allowing the joint to adapt to changing geometric relationships during assembly and operation, thereby eliminating the need for complex pre-adjustment procedures.
Solution Approach 2:
The joint allows for parameter changes in the angular position and radial location of the rollers relative to the driveshaft and cylinder block. By varying the displacement angle and adjusting the roller carrier positions, the system can accommodate different distance variations without requiring complex assembly procedures, thus resolving the contradiction between adaptability and assembly simplicity.
2Manufacturing precision
If complex assembly processes are used to achieve precise alignment, then alignment precision is improved, but hydraulic fluid is contaminated and dirt is introduced into the hydrostatic unit
Solution Approach 1:
The synchronizing joint is designed with self-aligning capabilities through its roller mechanism, which automatically adjusts to the correct position during assembly. This self-service feature eliminates the need for complex manual alignment procedures that would otherwise require disassembling and reassembling components, thereby preventing hydraulic fluid contamination and dirt introduction while maintaining high alignment precision.
Solution Approach 2:
The roller carriers are pre-configured with embossed areas that guide the rollers into their correct positions during assembly. This preliminary action ensures proper alignment is achieved automatically as components are brought together, eliminating the need for subsequent adjustment procedures that would expose the hydraulic system to contamination risks.
3Ease of manufacture
If rollers are mounted on roller carriers without additional securing features, then the assembly process is simple, but rollers may slip off during handling and assembly
Solution Approach 1:
The roller carriers are equipped with localized embossed areas at specific positions where the rollers make contact. These embossed features provide localized retention without requiring complex securing mechanisms across the entire roller carrier structure. The embossed areas create sufficient friction and mechanical interference to prevent roller slippage during handling and assembly while maintaining the overall simplicity of the mounting process.
4Reliability
If additional securing features like snap rings are used to prevent roller slippage, then roller retention is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The invention extracts the essential securing function from complex multi-component retention systems (like snap rings and additional fasteners) and implements it through simple embossed areas on the roller carriers. These embossed features provide sufficient retention security for roller mounting without requiring additional parts or complex assembly steps, thereby maintaining high assembly speed and productivity while ensuring reliable roller retention.
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 enables secure roller mounting, simplifies assembly, prevents contamination of hydraulic fluid, and maintains the longevity of hydrostatic bent axis axial piston units by ensuring smooth operation and reducing the risk of dirt introduction.
Implementation Method 1
using a laser application to enhance the carrier diameter locally
Data Source
AI summary
A joint for the angularly adjustable drive-connection of a cylinder block and a driveshaft of a hydrostatic bent axis piston unit. The joint has a shank which is rotatable about its longitudinal axis defining a joint axis, on both ends of the shank roller carriers project radially and basically perpendicular to the joint axis. On each roller carrier a roller is provided rotatable around a roller axis. The rollers are secured in axial direction against slipping-off of the roller carriers by means of an embossed area located axially outside of the roller on the respective distal end portion of the roller carrier.