Integrated Pinion Bearing Coupling Assembly for Driveline Torque Transfer
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Solution Overview
Problem
Conventional power transfer systems for four-wheel drive and all-wheel drive vehicles face challenges in efficiently distributing drive torque while maintaining reduced weight and packaging efficiency, particularly in the support and coupling of pinion shafts within hypoid gearsets.
Innovation Solution
An integrated pinion-bearing-coupling (PBC) assembly is introduced, featuring a pinion head secured to a tubular shaft segment via a deformation process, with a lock collar and bearing unit, to enhance the support and coupling of pinion shafts, improving torque transfer and reducing weight and packaging requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separate pinion shaft and coupling components are used, then ease of manufacture and assembly are improved, but device complexity and packaging volume increase
Solution Approach 1:
The patent combines the pinion shaft and coupling components into a single integrated PBC assembly. The pinion shaft is formed as one piece with the coupling flange and bearing support features, eliminating the need for separate coupling components and reducing the number of parts that need to be manufactured and assembled.
2Ease of manufacture
If conventional separate pinion shaft and coupling components are used, then ease of assembly is improved, but packaging volume and weight increase
Solution Approach 1:
The integration of pinion shaft and coupling into a single PBC assembly reduces the overall volume required for packaging and installation. The combined structure eliminates gaps and spacing requirements between separate components, allowing for more compact packaging and reduced installation space in the vehicle.
3Weight of moving object
If integrated PBC assembly is used, then weight and packaging volume are reduced, but manufacturing complexity increases
Solution Approach 1:
While the PBC assembly is integrated, the patent employs a deformation process that segments the manufacturing steps into distinct phases: initial forming of the pinion shaft, positioning of bearing components, and controlled deformation to create interference fits. This segmentation of the manufacturing process makes the complex integrated structure feasible to produce.
Solution Approach 2:
The patent utilizes controlled plastic deformation as a manufacturing parameter to create the interference fit between the pinion shaft and coupling components. By changing the physical state and dimensions of the shaft through deformation, the integrated structure achieves secure attachment without requiring complex fastening operations or multiple assembly steps.
4Ease of manufacture
If conventional pinion shaft support is used, then manufacturing simplicity is maintained, but torque transfer efficiency decreases
Solution Approach 1:
The controlled deformation process creates an interference fit between the pinion shaft and coupling components, changing the dimensional parameters of the shaft to achieve optimal torque transfer. This deformation-based connection provides superior torque transfer efficiency compared to conventional clearance-fit or fastened connections, while still maintaining manufacturing simplicity through a single-step deformation process.
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 PBC assembly effectively secures the pinion head to the shaft segment, optimizing torque transfer and reducing weight and packaging needs, thereby enhancing the efficiency and performance of power transfer systems in four-wheel drive and all-wheel drive vehicles.
Implementation Method 1
utilizing a deformation process to secure the pinion head to the shaft segment
Data Source
AI summary
An integrated pinion, bearing and coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles. The PBC assembly includes a pinion unit having a pinion gear segment and a pinion stub shaft segment, and a coupler unit having a coupling flange segment and a coupler shaft segment. The pinion stub shaft segment surrounds and is in press fit engagement with the coupler shaft segment. A portion of the coupler shaft segment is deformed to be retained within one of a receiver groove and raised projections formed in the pinion stub shaft segment so as to fixedly secure the coupler unit to the pinion unit.