Multi-piece Spool Design for Axle Assembly Weight Reduction
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Solution Overview
Problem
Conventional one-piece spools for automotive axle assemblies are heavy, lack strength, and have limitations in delivering torque under varying traction conditions, necessitating a lighter, stronger, and more reliable alternative.
Innovation Solution
A multiple-piece spool design comprising two aluminum spool pieces with steel spline inserts and a hollow interior, featuring a seal and attachment mechanism to securely lock and rotate axles together, while reducing weight through lightening holes and a bell-shaped structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional one-piece spool is used, then the structure is simple and manufacturing is easy, but the weight is excessive and strength is insufficient
Solution Approach 1:
The spool is divided into multiple separate pieces (first spool piece and second spool piece) that are assembled together. This segmentation allows each piece to be optimized for strength while using lighter materials, and enables the use of hollow interiors to reduce weight without compromising overall structural integrity.
Solution Approach 2:
The spool employs composite construction by assembling multiple pieces with different material properties. The first and second spool pieces can be made from materials optimized for their specific functions, and the assembly uses fasteners and sealing elements to create a composite structure that achieves both weight reduction and enhanced strength.
2Reliability
If a conventional one-piece spool is used, then the design is simple, but torque delivery under varying traction conditions is suboptimal
Solution Approach 1:
The segmented spool design allows for independent optimization of each piece's geometry and material properties to enhance torque delivery. The first and second spool pieces can be designed with specific features for better torque transmission, and the assembly provides improved torque delivery under varying traction conditions while maintaining manageable complexity through modular construction.
3Weight of moving object
If the spool is made from aluminum to reduce weight, then weight decreases, but strength may be compromised
Solution Approach 1:
The aluminum spool pieces are assembled into a composite structure that achieves both weight reduction and enhanced strength. The modular assembly allows for strategic placement of fasteners and reinforcement elements that compensate for the lower strength of aluminum while maintaining weight advantages over solid steel construction.
Solution Approach 2:
Dividing the spool into multiple aluminum pieces allows for hollow interiors and optimized geometries that reduce weight while the assembly structure provides overall strength. Each piece can be designed to leverage aluminum's high strength-to-weight ratio while the combined structure achieves the necessary load-bearing capacity.
Data Source
AI summary
A multi-piece spool includes a first spool piece and a second spool piece. The first spool piece is configured to receive a first axle. The second spool piece is configured to receive a second axle. The first spool piece is configured to attach to the second spool piece where the first spool piece and the second spool piece are rotationally affixed about a longitudinal axis created through the first axle and the second axle. Wherein, the multi-piece spool is configured for locking the first axle with the second axle for rotating the first axle and the second axle together when the first spool piece is attached to the second spool piece.