Thin-Walled Universal Joint Structure for Lightweight Propeller Shafts
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Solution Overview
Problem
Existing automobile propeller shafts face challenges with high cost, complex processing technology, low processing efficiency, and inability to meet mass production requirements due to material delamination, deformation, and high torque loads, particularly in lightweight designs using aluminum alloy and carbon fiber.
Innovation Solution
A lightweight universal joint and splined pair design that optimizes the stress state by transferring torque through fixed wings, bearings, and rolling elements, reducing the socket's load, and using thin-walled structures with chipless machining, while the splined pair optimizes material distribution and reduces stress and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight materials such as aluminum alloy and carbon fiber are used to reduce propeller shaft weight, then weight is reduced, but cost increases and production difficulty increases
Solution Approach 1:
The patent changes the material parameter from traditional lightweight materials (aluminum alloy, carbon fiber) to thin-walled steel structure, achieving weight reduction while maintaining manufacturability and cost-effectiveness
Solution Approach 2:
The patent applies thin-walled structure design to the socket and spline components, using thin-walled steel tubes with optimized wall thickness to achieve weight reduction without compromising structural integrity or manufacturing ease
2Weight of moving object
If the socket wall thickness is reduced to decrease weight, then weight is reduced, but structural strength decreases and deformation occurs under torque
Solution Approach 1:
The patent optimizes the wall thickness parameter of the socket to a specific range (0.5-3mm) and changes the structural configuration by adding reinforcement ribs, achieving weight reduction while maintaining sufficient strength through parameter optimization rather than simple thinning
Solution Approach 2:
The patent applies local reinforcement ribs at critical stress areas of the socket, providing localized strength enhancement where torque loads are highest, allowing the overall wall thickness to be reduced while maintaining structural integrity at key locations
3Weight of moving object
If the socket structure is optimized to reduce weight, then weight is reduced, but processing complexity increases and processing efficiency decreases
Solution Approach 1:
The patent adopts thin-walled tube structure for the socket that can be manufactured using standard cold drawing or extrusion processes, avoiding complex machining while achieving weight reduction, thus maintaining high processing efficiency
Solution Approach 2:
The patent segments the socket structure into modular components with reinforcement ribs that can be formed through standard metal forming processes, simplifying manufacturing steps and improving processing efficiency compared to monolithic complex structures
4Strength
If the splined pair uses traditional design with small diameter and large wall thickness, then structural strength is sufficient, but weight is excessive and material distribution is suboptimal
Solution Approach 1:
The patent changes the dimensional parameters of the splined pair by increasing the outer diameter and reducing wall thickness, optimizing the diameter-to-thickness ratio to achieve better material distribution, reduced weight, and improved bending capacity while maintaining sufficient strength
Solution Approach 2:
The patent optimizes the spline tooth geometry and material distribution locally within the splined pair structure, concentrating material where stress is highest (in the spline teeth) while reducing material in less critical areas, achieving weight reduction without compromising load-bearing capacity
Data Source
Figure 1~3
Figure 4~7
Figure 8~9(b)
AI summary
A lightweight universal joint, a splined pair, and a propeller shaft are provided. The lightweight universal joint includes a socket (3), a ball (1), and a straight shaft (2), where the socket (3) is a thin-walled structure, and is not configured to transfer a transmission torque; the ball (1) is provided in the socket (3) in a hinged manner, and the ball (1) is provided with a transmission hole; the straight shaft (2) runs through the transmission hole; two ends of the socket (3) are connected to fixed wings (8), respectively; and each of the fixed wings (8) is provided with a carrying hole (8-1) and a transmission key (8-2). The lightweight splined pair includes a spline shaft (16) and a spline sleeve (17) that are thin-walled structures. The lightweight propeller shaft includes the lightweight universal joint and/or the lightweight splined pair. By forming the socket (3) and the splined pair into integrated thin-walled structures, the present disclosure achieves chipless or partial chipless machining, improves production efficiency and quality stability, reduces part weight and processing costs, and meets the demand for lightweight development of automobile parts.