Split Propshaft Bracket Assembly for Compact Shipping
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Solution Overview
Problem
Brackets for rotating shafts, such as vehicle propshafts, occupy significant space during manufacturing and shipping due to their assembly with the shaft, increasing costs.
Innovation Solution
A bracket design featuring a base with a mount body and receiver, where the receiver is flexible and resilient, allowing it to expand to receive the shaft assembly components, and a retainer that secures the assembly by applying tensile force, preventing separation and reducing the need for large, fixed brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bracket is assembled to the shaft during processing and shipping, then the shaft can be secured to the bracket, but the bracket consumes significant space in workstations and during shipping, increasing manufacturing and shipping costs
Solution Approach 1:
The bracket is divided into two separate components: a cylindrical part that fits around the shaft and a larger mounting bracket portion. These segments can be assembled together only when needed, allowing the shaft to be processed and shipped in a compact state without the space-consuming mounting bracket attached.
Solution Approach 2:
The cylindrical part of the bracket is designed to receive and enclose the shaft, with the shaft nesting inside the cylindrical portion. This nested configuration minimizes the overall volume during shipping while maintaining secure attachment when assembled.
2Ease of manufacture
If the shaft is part of an assembly that prevents later assembly of the bracket to the shaft, then the shaft can be processed independently, but the bracket must be assembled during processing which increases complexity
Solution Approach 1:
The cylindrical part of the bracket is pre-assembled to the shaft during shaft processing when access is available. This preliminary action secures the bracket in advance, eliminating the need for complex later assembly operations and allowing the shaft assembly to be processed independently before final bracket attachment.
Solution Approach 2:
The bracket assembly process is made dynamic and flexible, allowing assembly to occur at different stages depending on the specific situation. The design accommodates both early assembly during processing and later assembly when needed, adapting to the requirements of different manufacturing scenarios.
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 design allows for efficient assembly and shipping of propshafts without large brackets, saving space and reducing manufacturing and shipping costs while maintaining secure attachment to the vehicle.
Implementation Method 1
The receiver is flexible and resilient and applies a tensile force on the retainer when the retainer is coupled to the base
Data Source
AI summary
In at least some implementations, a bracket for a rotating shaft includes a base and a retainer. The base has a mount body and a receiver having a first portion coupled to the mount body, a second portion extending from the first portion at a first end of the second portion to a second end of the second portion, a seat and an opening. The opening is defined at least in part by an inner surface disposed around a center axis. The retainer has a first surface engaged with the seat and a second surface engaged with a retention surface of the mount body and the retainer prevents separation of the seat from the retention surface by a distance greater than the distance between the first surface and the second surface.