Split Drive Shaft Coupling for Clutch Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional drive trains require the removal of the transmission or engine for clutch replacement, making the process costly and complex due to the design's limitations, which increases the difficulty and expense of clutch repairs.
Innovation Solution
A multipart drive shaft with a transmission section, spline gear section, and coupling section, where the coupling is slidably mounted and secured with a threaded sleeve, allowing for the removal of the coupling section and subsequent drop-out of the clutch assembly without necessitating the removal of the transmission or engine, utilizing a tongue-in-groove configuration and threaded surfaces for alignment and securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the transmission is removed to replace the clutch, then the clutch can be accessed for repair, but the repair process becomes complex and expensive
Solution Approach 1:
The drive shaft is divided into multiple separable sections (first section, second section, third section) that can be independently removed. This segmentation allows the clutch assembly to be accessed by removing only specific shaft sections rather than the entire transmission, thereby simplifying the repair process while maintaining the ability to access the clutch for replacement
2Ease of repair
If the transmission is removed to replace the clutch, then the clutch assembly can be accessed, but the repair time and cost increase
Solution Approach 1:
The drive shaft is segmented into removable sections with coupling mechanisms that allow quick disassembly and reassembly. This enables mechanics to access and replace the clutch assembly without the time-consuming process of removing the entire transmission, significantly reducing repair time while maintaining full access to the clutch components
Solution Approach 2:
The drive shaft sections are designed with pre-configured coupling mechanisms (such as splines, keys, or interlocking features) that allow for rapid reassembly after clutch replacement. This preliminary design of the connection system eliminates the need for complex alignment and securing operations during repair, thereby reducing the overall repair time
3Ease of repair
If the drive shaft is made separable for easy clutch replacement, then repair becomes simpler, but the structural integrity and alignment may be compromised
Solution Approach 1:
The drive shaft is segmented into multiple sections that are reconnected through precision-coupled interfaces. These interfaces incorporate alignment features such as tapered surfaces, keyed connections, or splined interfaces that automatically ensure proper coaxial alignment when sections are joined, thereby maintaining rotational accuracy and structural reliability while enabling separable construction for easy repair
Data Source
AI summary
A multi-section drive shaft transmission section with threading about an exterior surface, and a spline gear section extending into a clutch assembly with similar threading about a portion of an exterior surface. Between the transmission and the spline sections is a coupling section, with mating surfaces complimentary to respective mating surfaces located on the spline gear and transmission sections. The mating surfaces are designed to let the coupling either slide out of place, or to be removed by sliding the spline gear section further into the pilot bushing. The coupling, spline gear and transmission sections are secured in place with an anodized threaded sleeve. The transmission coupling, and spline gear sections make up a portion of a vehicle drive train. The coupling section can be slidably removed allowing the spline gear section to slide out of the pilot bushing and over a tab or tongue of the transmission section, which enables the clutch assembly to be removed from the drive train.