Modular Fan Drive Hub Input Shaft Assembly
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Solution Overview
Problem
Fan drive hub assemblies for medium and heavy-duty vehicles face challenges with heavy, one-piece cast iron input shafts that are specific to particular models, necessitating a robust yet lighter weight input shaft assembly that is easy to manufacture and modular enough to be used across multiple models.
Innovation Solution
A modular input shaft assembly featuring two individual bearing housings connected via a coupler, allowing for adjustable axial length and the ability to integrate various input members, such as pulleys, to accommodate different fan drive hub assembly designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece cast iron input shaft is used, then the input shaft is robust and strong, but it is extremely heavy and specific to particular models
Solution Approach 1:
The input shaft is divided into multiple separable components: a reusable bearing housing assembly (including front and rear housings with integrated bearings) and a model-specific input shaft section. This segmentation allows the heavy cast iron bearing housing to be reused across multiple models while only the lighter, model-specific sections need to be changed, significantly reducing overall weight and enabling modularity.
Solution Approach 2:
The patent employs composite construction by combining different materials and manufacturing methods - the bearing housings are formed as composite assemblies of cast iron housing structures with pressed-in bearing components, while the input shaft sections can be made from lighter materials or optimized geometries specific to each model, achieving both strength and weight reduction.
2Strength
If a one-piece cast iron input shaft is used, then the input shaft is robust, but it is extremely heavy and difficult to manufacture for multiple models
Solution Approach 1:
The input shaft assembly is segmented into a universal bearing housing component that can be manufactured once and reused across multiple models, and model-specific input shaft sections. This eliminates the need to manufacture complete one-piece shafts for each model, significantly improving manufacturing efficiency and reducing tooling costs while maintaining the robustness of the bearing housing structure.
Solution Approach 2:
The bearing housing assembly is designed as a universal component that can accommodate multiple input shaft configurations through standardized interfaces (such as keyed connections or splines). This multi-functional design allows a single housing design to serve multiple fan drive hub assembly models, simplifying manufacturing and inventory management.
3Weight of moving object
If a modular input shaft assembly is used, then the weight is reduced and manufacturing is easier, but the device complexity increases
Solution Approach 1:
While segmentation into multiple components does increase assembly complexity, the patent mitigates this by designing simple, standardized connection interfaces between components (such as keyed shafts, splines, or flanged connections with bolts). The modular design allows components to be assembled in a straightforward sequence without complex alignment procedures, keeping the increase in complexity manageable while achieving weight reduction.
Solution Approach 2:
The patent combines the bearings, bearing housings, and sealing elements into integrated assemblies that function as unified components. By merging these elements into pre-assembled units (such as pressed-in bearing assemblies with integrated seals), the overall system complexity is reduced despite the modular nature of the input shaft, as these merged components interact as single functional units.
Data Source
AI summary
A fan drive hub assembly having a modular input shaft assembly that includes a rear bearing housing, a front bearing housing, and a coupler that is fixedly coupled to the rear and front bearing housings.