Angled Tailgate Driveshaft Wobble Coupling for Tight Packaging
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Solution Overview
Problem
Existing drive systems for powered vehicle closures, such as tailgates, face challenges in efficiently pivoting closures while maintaining a secure and weather-tight seal, especially when dealing with angled orientations and space constraints.
Innovation Solution
A drive system comprising a motor, couplers, and an angled driveshaft that uses wobble connections to allow for angled orientations and rotational fixing, enabling efficient pivoting of vehicle closures while accommodating space constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional parallel driveshaft connection is used, then the structure is simple and easy to manufacture, but it cannot accommodate angled orientations and space constraints in vehicle closures
Solution Approach 1:
The wobble connection employs a spherical joint mechanism that allows the driveshaft to dynamically adjust its angle relative to the coupler during operation. The spherical interface enables rotational movement in multiple directions, accommodating the angled orientation requirements of vehicle closures while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent transitions from a traditional parallel-axis driveshaft connection to an angled connection by introducing a third dimensional degree of freedom through the wobble connection. This allows the driveshaft to operate at angles relative to the coupler axis, enabling installation in space-constrained environments with angled mounting positions.
2Reliability
If a wobble connection with engaging surfaces is used, then rotational fixing is achieved, but the manufacturing precision requirements increase
Solution Approach 1:
The wobble connection utilizes spherical surfaces for the engaging interfaces between the driveshaft and coupler. This spherical geometry naturally provides rotational fixing capability while being more tolerant of manufacturing variations compared to flat or precision-machined surfaces. The curved surfaces allow for self-alignment and accommodate minor dimensional variations.
Solution Approach 2:
The spherical engaging surfaces in the wobble connection enable self-alignment and self-adjustment during assembly and operation. The geometry of the spherical interfaces automatically positions the components correctly, reducing the need for high-precision manufacturing and manual alignment procedures.
3Volume of moving object
If the driveshaft is offset from the closure hinge axis, then space constraints are accommodated, but the mechanical stress on the connection increases
Solution Approach 1:
The wobble connection creates a dynamic stress distribution through its spherical joint mechanism. As the closure moves through its range of motion, the spherical interface continuously adjusts the load path, distributing mechanical stresses more evenly across the connection rather than concentrating them at fixed points. This dynamic adaptation reduces peak stresses despite the offset configuration.
Data Source
AI summary
A drive system for a tailgate and including a drive unit having a first coupler supported for rotation about a first longitudinal axis and defining a receptacle. A second coupler including a first side and a second side configured to engage with a hinge component of a vehicle and defining a second longitudinal axis. A driveshaft extends between the first and second couplers at an angled orientation relative to the first and second axes via wobble connections formed between a first end of the driveshaft and the first coupler and between a second end of the driveshaft and the first side of the second coupler.