Slip Axle Input Arrangement Eliminates Companion Flange
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Solution Overview
Problem
Conventional drive axle systems are complicated and costly due to the need for companion flanges, which increase weight, noise, vibration, and harshness, and laborious installation processes.
Innovation Solution
An input arrangement for drive axle systems that eliminates the need for companion flanges by using a splined sleeve and input shaft with a splined recess, forming a slip joint that allows axial movement and power transfer without additional flanges, thereby reducing weight and noise, vibration, and harshness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If companion flanges are used to join the Cardan shaft with the drive axle system, then power transfer is achieved, but weight increases and noise, vibration and harshness worsen
Solution Approach 1:
The patent merges the companion flange and Cardan shaft into a single integrated input shaft assembly. The input shaft directly receives power from the Cardan shaft without requiring a separate companion flange, thereby eliminating unnecessary components while maintaining effective power transfer to the differential assembly.
Solution Approach 2:
The patent extracts and eliminates the companion flange component from the drive axle system. By removing this unnecessary intermediate component, the design achieves direct power transfer from the Cardan shaft to the differential, reducing weight and eliminating the source of noise, vibration and harshness associated with the companion flange.
2Power
If companion flanges are used to join the Cardan shaft, then power transfer is enabled, but device complexity increases
Solution Approach 1:
The patent combines the functions of the companion flange and input shaft into a single integrated component. This merging eliminates the need for separate assembly steps and reduces the number of parts, thereby simplifying the overall device complexity while maintaining power transfer capability.
Solution Approach 2:
The patent removes the companion flange component entirely from the system. By extracting this unnecessary element, the design achieves a simpler, more straightforward power transfer path from the Cardan shaft directly to the differential assembly, reducing both part count and assembly complexity.
3Stability of the object's composition
If companion flanges are installed prior to Cardan shaft attachment, then proper alignment is achieved, but installation labor increases
Solution Approach 1:
The patent eliminates the companion flange component that necessitates the multi-step installation process. By removing this intermediate component, the installation is simplified to a single direct attachment of the input shaft to the Cardan shaft, thereby reducing installation time and labor while maintaining proper alignment through the integrated design.
4Adaptability or versatility
If slip joint is incorporated in the Cardan shaft, then axial movement is accommodated, but cost and complexity increase
Solution Approach 1:
The patent integrates the slip joint functionality directly into the input shaft assembly rather than incorporating it into the Cardan shaft. This merging allows axial movement to be accommodated at the input shaft where it is needed, while the Cardan shaft itself remains simpler in design.
Solution Approach 2:
The patent uses the input shaft as an intermediary component that absorbs the complexity of the slip joint mechanism. By placing the slip joint in the input shaft rather than the Cardan shaft, the design accommodates axial movement while keeping the Cardan shaft simpler and easier to manufacture.
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 input arrangement simplifies assembly, reduces weight and noise, vibration, and harshness, and lowers costs by eliminating the need for companion flanges and associated components, while maintaining effective power transfer and axial movement.
Implementation Method 1
The first splined portion is complimentary to and axially slidably engageable with the splined recess of the splined sleeve
Data Source
AI summary
An input arrangement for a drive axle system and a drive axle system are provided. The input arrangement comprises a splined sleeve and an input shaft. The splined sleeve has a first end drivingly engaged with a portion of a driveshaft and a second end which defines a splined recess. The input shaft has a first splined portion on an end of the input shaft. The first splined portion is complimentary to and axially slidably engageable with the splined recess of the splined sleeve. The input arrangement for a drive axle drive system eliminates a need for a companion flange, reduces a weight of the drive axle system, and reduces noise, vibration and harshness.