Plug-in Propshaft Assembly Tool with Bi-directional Thrust
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Solution Overview
Problem
Manual assembly of powertrain components with plug-in constant velocity joints requires high insertion forces and lacks reliable verification of successful coupling, making the process inefficient and prone to errors.
Innovation Solution
A power tool with bi-directional thrust features engages the CV joint and powertrain components to apply compression and expansion forces, ensuring full insertion and verification of the snap ring interlock without manual intervention, using actuators and sensors to monitor and control the forces applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual insertion method is used to attach propshaft component to powertrain component, then assembly process is simple, but insertion forces become undesirably high and verification of successful coupling is difficult
Solution Approach 1:
The patent replaces the manual mechanical insertion process with a power tool that applies controlled mechanical forces through thrust features. The power tool uses actuators to generate and control the insertion forces, substituting human manual operation with an automated mechanical system that can precisely control the magnitude and direction of forces applied during assembly.
Solution Approach 2:
The patent introduces thrust features as intermediary elements between the power tool and the component being assembled. These thrust features (such as flanges, channels, or sockets) serve as contact points that transmit the controlled forces from the power tool to the propshaft and powertrain components, enabling precise force application while protecting the actual coupling interfaces.
2Device complexity
If manual assembly verification is performed, then process is simple, but verification of successful coupling is unreliable and difficult
Solution Approach 1:
The patent incorporates sensors that detect when the snap ring interlock has successfully engaged during the insertion process. This feedback mechanism provides real-time information to the power tool controller, which can then confirm successful coupling or indicate if rework is needed. The system continuously monitors the insertion process and provides feedback on whether the coupling has been properly established.
Solution Approach 2:
The patent replaces manual visual inspection and verification with an automated sensing system. The sensors detect mechanical engagement of the snap ring interlock and provide electronic signals to confirm successful coupling, substituting unreliable human judgment with objective, automated detection that can reliably verify the assembly state.
3Extent of automation
If power tool with actuators is used to apply compression force, then insertion process is automated and verification is improved, but device complexity increases
Solution Approach 1:
The patent designs the power tool to perform multiple functions: applying compression forces during insertion, holding components in position, and verifying successful coupling through sensor detection. The same thrust features and actuators used for insertion also serve during verification, eliminating the need for separate verification equipment and reducing overall system complexity despite the automated capabilities.
Data Source
AI summary
A plug-in constant velocity (CV) joint is assembled to a powertrain component using a power tool. The CV joint and powertrain component connect via a splined shaft coupling with a snap ring interlock. External bi-directional thrust features on the joint and component engage first and second arms of the power tool after the splined shaft coupling is partially inserted by hand. The arms are relatively movable along a longitudinal direction, and an actuator selectively applies a compression force to the bi-directional thrust features adapted to fully insert the splined shaft coupling and engage the snap ring interlock. The power tool monitors the compression force to detect the full insertion. The actuator automatically applies a predetermined expansion force to the bi-directional thrust features to verify engagement of the snap ring interlock, wherein the predetermined expansion force is less than a force sufficient to disengage the snap ring interlock.