Adjustable-Angle Mechanical Joint for Dynamic Load Durability
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Solution Overview
Problem
Existing universal joints fail under dynamic loading conditions, limiting their use in applications requiring high durability and stability, such as drive trains, aircraft controls, and marine propulsion systems.
Innovation Solution
A mechanical joint design featuring a housing with a cap ring and drive puck, utilizing high-wear materials and bearings to enhance durability and stability, allowing for efficient transfer of rotational motion between axially unaligned shafts, and adjustable angle configurations for optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a structurally simple universal joint is used, then the moment of inertia is minimized, but the dynamic loading capacity is insufficient
Solution Approach 1:
The drive puck incorporates a composite structure with a core made of high-strength material (such as titanium or steel) and an outer contact surface made of wear-resistant material (such as ceramic or coated composite). This composite construction increases dynamic loading capacity while keeping the overall moment of inertia low by using lightweight high-strength materials in the core structure.
Solution Approach 2:
The patent applies different material properties to different parts of the drive puck: the core uses high-strength material for structural integrity under dynamic loads, while the outer contact surface uses wear-resistant material for extended service life. This localized differentiation allows the joint to handle higher dynamic loads without significantly increasing overall mass.
2Reliability
If the universal joint structure is improved to increase dynamic loading capacity, then reliability improves, but the moment of inertia increases
Solution Approach 1:
By using composite materials with high strength-to-weight ratios (such as titanium alloy core with ceramic coating), the joint achieves enhanced dynamic loading capacity without proportionally increasing mass, thus minimizing the impact on moment of inertia and maintaining fast response characteristics.
Solution Approach 2:
The drive puck is segmented into functional zones: a structural core for strength and an outer contact layer for wear resistance. This segmentation allows each part to be optimized independently - the core for minimal mass with maximum strength, and the contact surface for durability - resolving the contradiction between reliability and speed.
3Duration of action of stationary object
If high-wear material is applied to the outer contact surface, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The wear-resistant material is applied to the outer contact surface during the manufacturing process through techniques such as plasma spraying, thermal spraying, or co-molding. By performing this material application as a preliminary action during manufacturing rather than as a separate post-processing step, the service life is extended while manufacturing complexity is minimized.
Solution Approach 2:
The drive puck is manufactured as a composite component with the wear-resistant material integrated into the structure. This can be achieved through co-molding, metal matrix composite fabrication, or surface deposition techniques performed during manufacturing, thereby extending service life without requiring complex multi-step assembly processes.
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 mechanical joint design significantly improves the dynamic loading capacity and stability of universal joints, enabling their use in demanding applications by providing a robust and efficient means of transferring rotational motion while maintaining structural integrity.
Implementation Method 1
An outer contact surface of the first drive puck is slidingly engaged within the channel and with the first and second channel segments
Implementation Method 2
The outer contact surface includes a high-wear material
Implementation Method 3
A pin aperture is disposed through the first and second wings. A pin is disposed within the pin aperture. A first shaft is rotatably coupled with the drive puck by the pin
Data Source
AI summary
A mechanical joint for transferring rotational motion between shafts at an angle and related assemblies. The assemblies can include both fixed and adjustable-angle joint housings for providing high torques in hard to reach areas. Other assemblies include improvements in inboard marine drives that correct the prop angle to generally align with the direction of travel of the boat and outboard marine drives with improved drive trains.