Single-Weld Driveline Connecting Assembly Reducing Weight
Solution Overview
Problem
Existing connecting assemblies for motor vehicle drivelines are complex and costly to produce and assemble, requiring multiple bolts and welds, which increases production time and weight.
Innovation Solution
A connecting assembly with a housing comprising two flange portions, where only the second flange portion is welded to the driving gear, allowing for a single weld to connect three components, reducing production complexity and weight by eliminating additional connecting means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple bolts and welds are used to connect housing parts to the driving gear, then the connection strength and reliability are improved, but the production complexity, production time, and weight increase
Solution Approach 1:
The patent combines multiple connection functions into a single welding operation. The second housing part is welded directly to the driving gear, simultaneously achieving both connection and positioning functions that would otherwise require separate bolts and welds. This merging of functions reduces the number of connecting means from multiple bolts and welds to a single weld, thereby reducing production complexity while maintaining connection strength.
Solution Approach 2:
The patent extracts and eliminates unnecessary connecting means (bolts and additional welds) from the assembly. By designing the second housing part with an integrated flange portion that can be directly welded to the driving gear, the solution removes the need for separate bolt connections and positioning welds, simplifying the overall connection system while maintaining reliability.
2Reliability
If multiple bolts and connecting means are used, then the connection security is improved, but the weight of the assembly increases
Solution Approach 1:
The patent merges multiple connecting means into a single welded joint. The second housing part is directly welded to the driving gear, eliminating the need for separate bolts and additional connecting elements. This consolidation maintains connection security through the welded joint while removing the extra weight that would be introduced by multiple bolts and connecting means.
Solution Approach 2:
The patent replaces permanent mechanical connecting means (bolts) with a more efficient permanent connection (weld). The welded joint provides equivalent or superior connection security without the additional weight of multiple bolts and their associated holes and fastening elements.
3Strength
If multiple welds are performed to connect housing parts and driving gear, then the connection strength is improved, but the production time and cost increase
Solution Approach 1:
The patent combines multiple welding operations into a single welding step. The second housing part is welded directly to the driving gear in one operation, simultaneously achieving connections that would otherwise require multiple separate welds. This merging of welding operations maintains connection strength while significantly reducing production time and associated costs.
Solution Approach 2:
The patent incorporates positioning features directly into the design of the second housing part and driving gear interface. The flange portion geometry is designed to automatically position the housing part correctly relative to the driving gear before welding, eliminating the need for separate positioning welds or adjustment operations during assembly.
4Reliability
If additional connecting means such as bolts are used, then the connection reliability is improved, but the assembly weight and production cost increase
Solution Approach 1:
The patent extracts and eliminates the need for additional connecting means (bolts) from the assembly system. By designing the second housing part with an integrated flange that can be directly welded to the driving gear, the solution removes unnecessary connecting elements, reducing both material costs and assembly costs while maintaining connection reliability through the welded joint.
Solution Approach 2:
The patent merges the functions of multiple connecting means into a single welded connection. The direct weld between the second housing part and driving gear simultaneously provides both mechanical strength and positioning accuracy that would otherwise require separate bolts and alignment features, thereby reducing production cost while maintaining reliability.
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 solution enables quick, cost-effective production and assembly with high axial pretension, ensuring secure torque transmission without additional anti-rotation means, while maintaining improved radial and axial runout conditions.
Implementation Method 1
the second flange portion is welded to the driving gear
Implementation Method 2
there is formed an interference fit which is also referred to as a press fit
Implementation Method 3
the first flange portion is axially loaded by the shrinkage forces occurring while the weld is cooling
Data Source
AI summary
A connecting assembly (2), more particularly for being used in the driveline of a motor vehicle. The connecting assembly comprises a housing (7) which comprises a first housing part (8) with a first flange portion (10) and a second housing part (9) with a second flange portion, and a driving gear (6) which comprises a receiving portion (63) for receiving the housing and a supporting face (65) which laterally delimits said receiving portion, wherein the first flange portion of the first housing part is axially arranged between the supporting face of the driving gear and the second flange portion (12) of the second housing part, and wherein the second flange portion is welded to the driving gear. The invention also relates to a method of producing a connecting assembly.