Straight Axle Spline and Threaded Retention for Wheel Rotor Stability
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Solution Overview
Problem
Existing rear drive systems in vehicles, particularly in heavy-duty and off-road applications, lack a robust connection between the wheel rotor and the axle, leading to potential disengagement and instability.
Innovation Solution
A straight axle design with splines at both ends and a threaded section that secures the wheel rotor using a fastener, eliminating the need for a press fit and enhancing the connection through complementary splines and threaded engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a press fit connection is used between the wheel rotor and the axle, then the assembly is simpler, but the connection is not robust enough and may disengage
Solution Approach 1:
The connection structure is segmented into multiple functional elements: an externally threaded section on the axle, a fastener for threading into the axle, and complementary splines on both the axle and wheel rotor. This segmentation allows each element to perform a specific function (threaded engagement for axial retention, splines for torque transmission) thereby achieving a more robust connection than a simple press fit while maintaining reasonable structural complexity.
Solution Approach 2:
The connection mechanism uses a composite approach combining different types of mechanical engagement: external threading provides axial retention while complementary splines provide radial torque transmission. This composite connection method leverages the strengths of both threaded and spline engagements to create a connection that is more robust than either method alone, resolving the contradiction between reliability and complexity.
2Reliability
If a simple axle design is used, then manufacturing is easier, but the connection between wheel rotor and axle is insufficient
Solution Approach 1:
The axle is segmented into distinct functional sections: a first free end with splines for differential engagement, a threaded section for fastener retention, and a second free end with complementary splines for wheel rotor engagement. This segmentation allows standard manufacturing processes to be applied to each section independently, maintaining ease of manufacture while achieving robust connection through the combination of threaded and spline engagements.
3Strength
If externally threaded section with fastener is added to the axle, then the connection becomes more secure, but the axle structure becomes more complex
Solution Approach 1:
The axle is designed with multi-functionality: the externally threaded section provides axial retention through fastener engagement, while complementary splines on the same axle provide torque transmission and rotational engagement. This multi-functional design achieves strong connection through a single integrated axle component rather than requiring separate retention and drive elements, thereby increasing connection strength while limiting the growth of structural complexity.
Data Source
AI summary
A straight axle for a vehicle drive assembly including an elongated shaft having a first free end with a plurality of splines formed thereon and a second free end with an externally threaded section that defines the second free end and a plurality of splines that are formed on the elongated shaft behind the externally threaded section. The plurality of splines at the first free end of the elongated shaft and the plurality of splines at second free end of the elongated shaft are configured to engage with complementary splines on associated drive components, and the externally threaded section is configured to receive a fastener that retains one of the associated drive components on the elongated shaft.