Hollow Shaft Plug Mounting with Offset and Tilt Compensation

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Solution Overview

Problem

Existing devices for mounting plugs in hollow shafts often result in increased joining forces due to production tolerance-related inclined positions or axial offsets, leading to potential damage and the need for costly reworking to achieve close tolerance requirements in radial and axial runout.

Innovation Solution

A device comprising a radially adjustable holding device and an inclinable joining device that compensates for axial offsets and inclined positions between the plug and hollow shaft, allowing for precise alignment and mounting with high radial and axial runout quality, using a floatingly mounted plate and ball bearing for radial adjustability and a centring pin for centring and play.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional mounting devices are used to mount plugs in hollow shafts, then the mounting process is simple, but production tolerance-related inclined positions or axial offsets cause increased joining forces, potential damage, and costly reworking

Engineering Contradiction:

Improveradial and axial runout qualityVSAvoiddevice structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The holding device is made radially adjustable relative to the hollow shaft axis, allowing dynamic compensation for axial offsets between plug and hollow shaft. The joining device is made inclinable to dynamically compensate for angular deviations between axes during the mounting process, transforming static positioning into dynamic adaptive positioning.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The device allows changing geometric parameters (radial position of holding device, inclination angle of joining device) to compensate for deviations. By adjusting these parameters, the system adapts to production tolerances rather than requiring perfect initial alignment.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If close tolerance requirements are enforced without compensation mechanisms, then high radial and axial runout quality is achieved, but elaborate machining and reworking are required leading to substantial additional costs

Engineering Contradiction:

Improveradial and axial runout qualityVSAvoidcost of machining and reworking

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The compensation for axial offsets and inclined positions is performed preliminarily during the mounting process itself, before final joining. This preliminary adjustment prevents the need for subsequent elaborate machining and reworking operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The device converts the harmful effect of production tolerances (inclined positions and axial offsets) into a beneficial adjustment mechanism. The radially adjustable holding device and inclinable joining device transform these deviations into adjustable parameters that can be compensated for, turning a problem into a solution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If axial offsets and inclined positions are not compensated, then the mounting process is straightforward, but seizing can occur and plugs may dig into hollow shaft material causing damage

Engineering Contradiction:

Improvemounting process simplicityVSAvoidjoining quality

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The dynamic adjustability of the holding device (radial adjustment) and joining device (inclination adjustment) allows the system to adapt to misalignments during operation, preventing seizing and damage while maintaining ease of operation through automated or manual adjustment mechanisms.

Inventive Principle:

Principle #15Dynamics

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

Enables precise alignment and mounting of plugs in hollow shafts, eliminating the need for costly reworking and ensuring high radial and axial runout quality, even for parts with stringent tolerance requirements.

Implementation Method 1

the plate is adjustably mounted in the radial direction relative to the hollow shaft via an air cushion or a ball bearing

Methodology Applied

Scientific EffectBall bearing: Ball Bearing

Implementation Method 2

the plate is adjustably mounted in the radial direction relative to the hollow shaft via an air cushion or a ball bearing

Methodology Applied

Scientific EffectAir cushion: Air Lubrication

Data Source

PatentUS11484975B2Method and device for mounting a plug in a hollow shaft

Publication Date: 2022.11.01 MAHLE INT GMBH

AI summary

A method and device for mounting a plug in a hollow shaft is disclosed. The device includes a holding device for holding the plug to be mounted and a joining device for sliding the hollow shaft onto the plug held in the holding device. The holding device is radially adjustable relative to an axis of the hollow shaft to compensate for an axial offset between the axis of the hollow shaft and an axis of the plug. The joining device can be inclined to compensate for an inclined position of the axis of the hollow shaft and the axis of the plug. The method includes pressing the joining device onto the hollow shaft from above and adjusting the holding device with the plug radially to the hollow shaft if the axial offset is present, and inclining the joining device if the inclined position is present.