Interchangeable Wheel Hub Modules for Reliable Engagement
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Solution Overview
Problem
Manual locking hub systems in four-wheel drive vehicles are unreliable due to the use of plastic components and complex designs, leading to high maintenance and repair costs, and often require full replacement of the hub lock instead of just the broken parts.
Innovation Solution
A modular wheel hub connecting device with a drive spline, cage, and cap that allows for interchangeable modules, enabling reliable engagement and disengagement of wheels with a pneumatic system and a bias to maintain the spline clutch in a disengaged position, reducing manufacturing and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual locking hub systems use plastic components to reduce cost, then manufacturing cost decreases, but reliability deteriorates as components break during use
Solution Approach 1:
The hub assembly is divided into modular components: a reusable hub body and interchangeable hub modules. The module contains wear-prone elements like the spline clutch and locking mechanism, while the hub body retains durable structural components. This segmentation allows replacement of only the failed module rather than the entire hub assembly, improving reliability while controlling manufacturing costs.
Solution Approach 2:
The invention changes the material parameter from plastic to metal for critical load-bearing and engagement components such as the spline clutch, locking mechanism, and drive spline. This material parameter change significantly improves reliability and durability while the modular architecture keeps overall manufacturing costs manageable through standardized production of interchangeable modules.
2Ease of operation
If manual locking hub systems use complex designs to achieve engagement, then engagement capability improves, but device complexity increases making disassembly difficult
Solution Approach 1:
The complex locking mechanism is segmented into a self-contained hub module that includes the spline clutch, locking mechanism, and associated components. This modular segmentation encapsulates the complexity within a standardized unit that interfaces simply with the hub body, maintaining engagement capability while reducing overall system complexity through standardized connections.
Solution Approach 2:
The hub module is designed as a universal interchangeable unit that can be installed on standardized hub bodies. The module integrates multiple functions (spline engagement, locking, sealing) into a single standardized component that works across different wheel applications, simplifying the overall system architecture while maintaining full engagement capability.
3Reliability
If full hub lock replacement is required when components break, then reliability is maintained, but loss of time increases due to complete replacement instead of part replacement
Solution Approach 1:
The hub system is segmented into a permanent hub body and removable hub modules. When a module fails, only that specific module needs to be replaced rather than the entire hub lock assembly. This segmentation enables rapid module swap-out while maintaining system reliability, significantly reducing repair time from complete replacement to simple module interchange.
Solution Approach 2:
The design enables selective replacement of failed hub modules while recovering and reusing the durable hub body and functional modules. Instead of discarding the entire hub lock assembly, only the specific failed module is replaced, and working modules can be recovered and reused in other applications, reducing both repair time and waste.
4Adaptability or versatility
If actuable hub systems are used to provide engagement/disengagement, then versatility improves, but device complexity increases leading to higher manufacturing and maintenance costs
Solution Approach 1:
The actuable hub system is segmented into a standardized hub body and interchangeable modules that can be swapped to provide different functions (locked, unlocked, free-wheeling). This segmentation provides versatility through module selection rather than complex internal mechanisms, reducing device complexity while maintaining the ability to adapt to different driving conditions.
Solution Approach 2:
Instead of providing actuation mechanisms within a single hub assembly, the invention inverts the approach by using interchangeable modules that are either locked or unlocked by design. The versatility comes from selecting and installing the appropriate module type rather than using complex actuation mechanisms, thereby reducing device complexity while maintaining adaptability.
Data Source
AI summary
A drive spline defines an inner profile configured to receive and mate with a drive axle and an outer profile configured to mate with a wheel hub. A cage surrounds and is engaged with the outer profile of the drive spline. The cage retains the drive spline axially and radially in position relative to the outer profile. A cap is coupled to an end of the wheel hub connecting device opposite the drive spline. The cap encloses the end of the hub connecting device.