Friction Welded Drive Shaft Module for Construction Machines

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Solution Overview

Problem

Conventional drive shafts in construction machines require high manufacturing and assembly costs, and complex shaft-hub connections lead to increased wear and replacement difficulties.

Innovation Solution

A drive shaft module composed of segments joined by friction welding, with a detachable mounting system for easy assembly and replacement, reducing manufacturing and assembly efforts, and featuring a hollow shaft design with a lubrication system for improved durability and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional shaft-hub connections (splined shaft gearing, force fits, key-and-slot joints) are used to fix force application and bearing elements to the shaft, then the connection provides structural stability, but manufacturing and assembly costs and efforts increase significantly

Engineering Contradiction:

Improvestructural stabilityVSAvoidmanufacturing and assembly costs and efforts

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces complex mechanical shaft-hub connections (splined shaft gearing, force fits, key-and-slot joints) with friction welding, a thermal-mechanical joining process. This substitution eliminates the need for intricate mechanical interlocking features while achieving equivalent or superior connection strength, thereby reducing manufacturing complexity and assembly efforts

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental joining parameter from mechanical interlocking to thermal-mechanical fusion through friction welding. By altering the joining mechanism from discrete mechanical features to a continuous welded joint, the patent simplifies the shaft design and reduces the number of manufacturing steps required

Inventive Principle:

Principle #35Parameter changes

2Strength

If conventional shaft-hub connections are used, then the shaft provides structural integrity, but replacement procedures require high efforts and downtime increases

Engineering Contradiction:

Improvestructural integrityVSAvoidreplacement procedures and downtime

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The patent divides the drive shaft into multiple separable segments that can be independently replaced. The friction-welded segments are designed to be detachable, allowing faulty sections to be quickly removed and replaced without replacing the entire shaft assembly, thereby reducing repair time and effort

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs a modular segment design where individual shaft segments can be economically replaced rather than the entire shaft. This approach treats shaft segments as replaceable components, reducing downtime and repair costs compared to conventional monolithic shaft designs

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Force

If conventional shaft-hub connections are used, then the connection provides force transmission, but relative motion between shaft and hub causes increased wear

Engineering Contradiction:

Improveforce transmissionVSAvoidwear resistance

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The friction welding process creates a homogeneous joint structure that eliminates the shaft-hub interface, thereby preventing the relative motion that causes wear in conventional connections

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Weight of moving object

If the drive shaft is designed as a hollow shaft, then weight is decreased and friction welding is facilitated, but structural strength may be reduced

Engineering Contradiction:

Improveshaft weightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The invention changes the shaft geometry from solid to hollow, optimizing the weight-to-strength ratio. The hollow configuration reduces material usage and weight while maintaining sufficient structural integrity for the application, and the friction welding process is adapted to accommodate the hollow geometry

Inventive Principle:

Principle #35Parameter changes

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

Significantly reduces manufacturing and assembly costs, simplifies installation and replacement procedures, and enhances the stability and maintainability of the drive shaft module, minimizing downtime in material conveyor systems.

Implementation Method 1

different shaft segments which are connected to each other by friction welding

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Implementation Method 2

a lubrication device within the drive shaft designed as a hollow shaft

Methodology Applied

Scientific EffectLubrication: Lubrication

Data Source

PatentUS9334896B2Drive shaft module for a construction machine

Publication Date: 2016.05.10 JOSEPH VOEGELE AG

AI summary

A drive shaft module for a material conveyor system of a construction machine comprises a drive shaft and at least one first mounting which is designed to hold the drive shaft at at least one first bearing location. The drive shaft comprises different segments which are joined by friction welding, and the mounting is connected to the drive shaft such that the complete drive shaft module may be detachably fixed, in a preassembled state, in or at the construction machine.