Thin-Walled Universal Joint and Splined Pair for Lightweight Propeller Shafts
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Solution Overview
Problem
Existing propeller shafts face challenges with high cost, complex processing technology, low processing efficiency, and inability to meet the requirements of mass production due to heavy weight and complex socket processing.
Innovation Solution
The solution involves a lightweight universal joint and splined pair design, where the socket is optimized to no longer transfer torque, instead serving as a lubrication seal, and the splined pair features a large diameter and small wall thickness design to improve material distribution and performance.
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 structural parameters of the socket from traditional thick-walled to thin-walled structure with optimized wall thickness, transforming the socket from a torque-bearing component to a sealing component. This parameter change enables weight reduction without requiring expensive lightweight materials, thereby resolving the contradiction between weight reduction and manufacturing ease
Solution Approach 2:
The patent segments the torque transmission function from the socket body by introducing separate torque transmission elements (such as ribs or加强 structures) that are integrated into the thin-walled socket. This segmentation allows the socket wall to be thin for weight reduction while maintaining overall structural strength through the distributed reinforcement elements
2Weight of moving object
If the socket wall thickness is reduced to reduce weight, then weight is reduced, but structural strength decreases and deformation risk increases
Solution Approach 1:
The patent applies local quality by creating non-uniform wall thickness distribution in the socket, with thicker sections at critical stress points (such as at the ends or at reinforcement rib locations) and thinner sections in non-critical areas. This local quality approach maintains structural strength where needed while reducing overall weight
Solution Approach 2:
The patent employs composite structural design by combining thin-walled metal socket with integrated reinforcement elements (such as stiffening ribs or embedded structural features) that create a composite-like structure, achieving high strength-to-weight ratio without using traditional composite materials
3Power
If the socket is designed to transfer torque, then torque transmission function is achieved, but wall thickness must be increased and weight increases
Solution Approach 1:
The patent segments the torque transmission function from the socket wall by introducing dedicated torque transmission elements (such as longitudinal ribs, circumferential stiffeners, or integrated spline structures) that are part of the socket structure but separate from the wall thickness design. This allows the wall to remain thin while torque is transmitted through these specialized structural features
Solution Approach 2:
The patent makes the socket structure multi-functional by designing the thin-walled socket to simultaneously serve as a sealing container and as a structural element with integrated torque transmission capability through reinforcement features, eliminating the need for thick walls solely for torque bearing
4Strength
If traditional socket processing technology is used, then structural strength is maintained, but processing complexity increases and production efficiency decreases
Solution Approach 1:
The patent merges the socket structure with integrated reinforcement features and torque transmission elements into a single thin-walled structure that can be manufactured as one piece using advanced forming techniques. This merging eliminates the need for separate manufacturing and assembly steps for reinforcement elements, thereby improving production efficiency while maintaining strength
Data Source
AI summary
A lightweight universal joint includes a socket, a ball, and a straight shaft, where the socket is a thin-walled structure, and is not configured to transfer a transmission torque; the ball is provided in the socket in a hinged manner, and the ball is provided with a transmission hole; the straight shaft runs through the transmission hole; two ends of the socket are connected to fixed wings, respectively; and each of the fixed wings is provided with a carrying hole and a transmission key. A lightweight splined pair includes a spline shaft and a spline sleeve that are thin-walled structures. A lightweight propeller shaft includes the lightweight universal joint and/or the lightweight splined pair. By forming the socket and the splined pair into integrated thin-walled structures, the lightweight propeller shaft achieves chipless or partial chipless machining, improves production efficiency and quality stability, and reduces part weight and processing costs.