Shaft Hub Connection via Segmented Welding and Press Fit
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Solution Overview
Problem
Existing pressure resistance welding methods for connecting shafts and hubs face challenges in achieving high joining strength and accuracy.
Innovation Solution
The method involves using a hub with first and second joining portions, where the shaft is pressed into the hub while the first joining portions are fused, forming a press fit between the second joining portions, which are only contacted at the end of the welding process, minimizing energy expenditure and ensuring a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressure resistance welding is used to connect shaft and hub, then joining strength is improved, but joining accuracy deteriorates
Solution Approach 1:
The joining area is divided into two separate joining portions (first and second joining portions) instead of using a single unified joining area. This segmentation allows the first joining portion to provide welded connection for strength while the second joining portion provides press-fit connection for accuracy, thereby resolving the contradiction between joining strength and joining accuracy.
Solution Approach 2:
Different joining mechanisms are applied to different local areas: the first joining portion uses pressure resistance welding to provide strong mechanical bonding, while the second joining portion uses interference fit (press-fit) to provide precise alignment and positioning. This local differentiation of joining quality allows each portion to optimize for its specific function.
2Strength
If single unified joining area is used for planar welding, then joining strength is improved, but device complexity increases
Solution Approach 1:
The joining area is segmented into two distinct portions with different functions. The first joining portion handles the welding operation while the second joining portion handles the press-fit operation. This segmentation allows for a more compact welding installation compared to a single large unified joining area, as each portion can be optimized for its specific function.
3Strength
If second joining portions are contacted at the beginning of welding, then joining strength is improved, but energy consumption increases
Solution Approach 1:
The first joining portion is welded while the second joining portions are kept separate and not yet in contact. This preliminary action allows the welding current to be concentrated on the first joining portion, minimizing energy loss. Only after the welding process is complete do the second joining portions come into contact to provide the press-fit connection, thereby avoiding unnecessary energy expenditure.
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
This approach enhances the strength and accuracy of the shaft-hub connection by combining a welded joint with a press fit, allowing for reliable absorption of axial forces and bending moments, while reducing energy consumption and enabling precise alignment.
Implementation Method 1
An electrical welding current is fed via the respective contact points of the parts that have been pressed together, so that the contact points fuse in the area of the first joining portions
Implementation Method 2
the molten metal in the area of the first joining portions can solidify
Data Source
AI summary
A method for connecting a shaft and a hub, the hub having a first joining portion and a second joining portion for a connection to corresponding joining portions of the shaft. The shaft and the hub are pressed together at contact points in the area of the first joining portions, while the second joining portions are not yet in contact with one another, and a welding current is fed via the contact points of the parts that have been pressed together, so that the contact points fuse. The shaft is pressed into the hub, while the first joining portions are being fused, until substantially a press fit is formed between the second joining portions.