Modular Drive Shaft Connector for Lightweight Torque Transfer
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Solution Overview
Problem
Existing drive shaft connections in vehicles face issues with weight, noise, delamination of carbon fiber layers, and inefficient torque transmission, particularly in high-power and high-torque applications, leading to potential drive loss and increased maintenance.
Innovation Solution
A modular connector with a profiled socket and centering rings, made of aluminum, securely fastens to a carbon fiber or aluminum tube using screws and adhesive, ensuring uniform force distribution and preventing delamination, while allowing easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional steel connections are used for drive shaft assembly, then structural strength is sufficient, but weight increases significantly
Solution Approach 1:
The connector is divided into multiple functional segments: an aluminum body for weight reduction, a profiled socket for mechanical engagement, screw holes for fastening, and a recess for mounting component integration. This segmentation allows each part to perform its specific function efficiently while maintaining overall strength despite using lighter aluminum material instead of steel
Solution Approach 2:
The connector combines aluminum material with steel mounting components through hybrid construction. The aluminum body provides weight reduction while steel mounting components (such as splined shafts, sliding joints, or tripod joints) provide the necessary strength and durability for high-torque applications. This composite approach resolves the contradiction between weight reduction and strength maintenance
2Weight of moving object
If carbon fiber tube is used for drive shaft, then weight is reduced, but delamination occurs at connection points
Solution Approach 1:
The profiled socket is designed with a specific geometric profile before assembly that pre-distributes mechanical loads across the carbon fiber tube surface. This preliminary structural design prevents stress concentration at connection points, thereby preventing delamination of carbon fiber layers during operation under high torque loads
Solution Approach 2:
The connector applies different structural qualities to different regions: the profiled socket provides distributed load bearing at the interface with the carbon fiber tube, while screw holes provide localized fastening points, and the recess provides mounting component attachment. This local differentiation of structural properties ensures that each region addresses specific stress patterns, preventing delamination while maintaining overall connection integrity
3Power
If conventional connection methods are used, then assembly is simple, but torque transmission efficiency is insufficient
Solution Approach 1:
The profiled socket incorporates curved and rounded geometric features that optimize the distribution of torque loads across the connection interface. The curved profile allows for better stress distribution compared to sharp angular features, enhancing torque transmission efficiency while the overall compact design maintains reasonable structural complexity
Solution Approach 2:
Multiple functions are merged into a single connector component: torque transmission through the profiled socket, fastening through screw holes, mounting component attachment through the recess, and structural support through the aluminum body. This merging of functions into one integrated component achieves high torque transmission efficiency without proportionally increasing device complexity
4Ease of repair
If modular connector is used for easy assembly, then maintenance becomes easier, but connection stability may be compromised
Solution Approach 1:
The modular connector is segmented into replaceable components: the aluminum body, the mounting component, and the screw fastening system. This segmentation allows the mounting component to be easily removed and replaced for maintenance or upgrades while the aluminum body remains intact. The screw holes provide secure fastening that maintains connection stability during normal operation, resolving the contradiction between ease of repair and connection stability
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 connector enhances torque transmission, reduces weight, minimizes noise, and extends the lifespan of the drivetrain system by providing a stable, durable, and lightweight connection that resists delamination and loosening.
Implementation Method 1
the connector insert can be bonded to the carbon tube using adhesive
Implementation Method 2
The key element of the invention is a securing system for the connections using fixing screws with Schnorr washers
Implementation Method 3
the connector is welded to the aluminum shaft tube
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3~4
AI summary
A modular connector (1) for an automotive drive shaft, characterized in that the connector has a ring shape made of metal, preferably aluminum. The body (5) of the connector is equipped on one side with a profiled socket (2) matching the shape of the mounting of a mounting element, and on the opposite side, the connector is fitted with a coupling (3) for the drive shaft tube. The body of the connector also includes openings (6) that enable its connection to the mounting element via screws passing through these openings. This solution is intended for use in the automotive industry.