Universal Joint Sleeve Angled Flex Stop Design
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Solution Overview
Problem
Existing universal joint support systems face challenges in achieving a durable and uniform attachment across different dimensions of universal joints, while ensuring clearance for rotation and maintaining strength of attachment.
Innovation Solution
The development of an improved sleeve system with an angled solid stop design, utilizing injection molding to create a more universal fit, with a process that includes specific mold cavity designs and heating elements to ensure proper material flow and attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid stop design is used, then the attachment strength is improved, but the clearance for rotation is reduced
Solution Approach 1:
The stop is designed with an angled configuration rather than a symmetric solid block. The angle is specifically designed to provide clearance for rotation while maintaining attachment strength through the angled support structure.
2Ease of operation
If the stop is thinned for clearance, then the rotation clearance is improved, but the attachment strength is reduced
Solution Approach 1:
Instead of thinning the stop uniformly, the design uses an angled configuration that distributes material strategically in different dimensions. The angled structure provides rotation clearance in one dimension while maintaining sufficient material thickness in other dimensions for attachment strength.
3Adaptability or versatility
If a universal fit design is used, then the adaptability to different dimensions is improved, but the manufacturing precision is reduced
Solution Approach 1:
The stop is designed with a universal configuration that can accommodate different universal joint dimensions. The angled design and proportional scaling allow a single design approach to work across multiple sizes while maintaining consistent attachment characteristics through the injection molding process.
4Ease of operation
If the stop material is reduced, then the clearance is improved, but the durability is reduced
Solution Approach 1:
The design uses material strategically distributed in a composite-like fashion, with the angled stop providing structural durability where needed while creating clearance spaces where material reduction is beneficial for rotation. The injection molding process ensures uniform material distribution for optimal durability-to-clearance ratio.
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
This solution provides a durable and uniform attachment to universal joints of varying dimensions, ensuring strength and clearance for rotation, thereby improving the repeatability and effectiveness of the universal joint support system.
Implementation Method 1
The process includes specific mold cavity designs and heating elements to ensure proper material flow and attachment
Data Source
AI summary
Uniformed improvement to the flex stop system with an effective fit and attachment thereof by improving overall fit to many different types of universal joints, and with the flex and movement for clearance needed with a greater angle of rotation.