Non-Cylindrical Drive Shaft for Axis Misalignment and Torsional Stiffness
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Solution Overview
Problem
Traditional drive shafts with constant cylindrical cross-sections lack the flexibility to accommodate shifting input and output axes, leading to potential misalignment and inefficiencies in dynamic behavior.
Innovation Solution
A drive shaft design featuring a portion where the outer diameter changes continuously through an infinite number of diameters across at least 15% of its axial length, combined with a spiral undulation on the outer periphery to enhance flexibility and torsional stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a constant cylindrical cross-section is used, then manufacturing is simple, but flexibility to accommodate shifting axes is poor
Solution Approach 1:
The patent applies parameter changes by varying the cross-sectional geometry along the shaft length. Specifically, it uses tapered sections where the diameter changes continuously, and bellows sections with variable cross-sectional areas, allowing the shaft to accommodate axial displacement and shifting axes while maintaining structural integrity.
Solution Approach 2:
The patent implements dynamics by creating a non-rigid, adaptable structure. The bellows sections with variable cross-sections enable the shaft to dynamically adjust its shape and length in response to axial forces and misalignment, transforming a static cylindrical form into a dynamic, flexible structure.
2Adaptability or versatility
If a constant cylindrical cross-section is used, then structural simplicity is maintained, but bending flexibility is insufficient
Solution Approach 1:
The patent applies local quality by creating regions with different geometric properties along the shaft. The bellows sections have locally varied cross-sections that provide enhanced bending flexibility where needed, while other sections maintain different geometries to provide structural support and torsional stiffness.
Solution Approach 2:
The patent uses curvature principles by employing bellows-like undulating shapes with variable cross-sections. These curved, non-linear geometries allow the shaft to bend and flex more effectively compared to straight cylindrical sections, accommodating misalignment and dynamic movement.
3Adaptability or versatility
If diameter variation is introduced, then flexibility is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent systematically applies parameter changes by defining specific geometric progression patterns for the variable diameter sections. These controlled variations, such as tapered sections and bellows with predictable cross-sectional changes, make the complex geometry more manageable for manufacturing while maintaining the desired flexibility.
4Productivity
If non-cylindrical portions are extended, then dynamic behavior is optimized, but structural complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the shaft into distinct functional sections: rigid cylindrical portions for structural support, tapered sections for gradual transition and flexibility, and bellows sections for axial compliance. This segmentation allows each portion to be optimized for its specific function while simplifying the overall design and manufacturing process.
Data Source
AI summary
A drive shaft extends between axial ends and has at least one portion through which an outer diameter of the drive shaft changes through an infinite number of diameters, with the at least one portion extending across at least 15% of an axial distance between the axial ends of the drive shaft. A drive shaft with a generally spiral undulation at its outer periphery is also disclosed.