Welded Shaft Module Structure for Lightweight Drive Trains
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Solution Overview
Problem
Existing shaft modules in drive trains are heavy and require multiple components, contributing to increased material usage and environmental impact.
Innovation Solution
A shaft module design featuring a tooth system with separate hubs and bearing seats, connected by welded joints, allowing for a self-supporting structure without a separate supporting shaft, using hollow gear wheels and integrated bearing races to reduce weight and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a traditional shaft module with separate supporting shaft and tooth system is used, then the structural integrity and load-bearing capacity are ensured, but the weight and material consumption increase
Solution Approach 1:
The tooth system is merged with the supporting shaft by forming the tooth system directly on the shaft as an integral structure. This eliminates the need for separate tooth systems and reducing the overall number of components, thereby reducing weight while maintaining structural integrity through the unified design.
Solution Approach 2:
The shaft is designed as a hollow structure with an internal cavity instead of a solid shaft. This extraction of material from the shaft's interior reduces the weight and material consumption while maintaining the necessary strength and load-bearing capacity through optimized wall thickness and structural design.
2Ease of manufacture
If multiple separate components are used to form the shaft module, then the manufacturing flexibility and assembly options are increased, but the device complexity and production cost increase
Solution Approach 1:
The tooth system and supporting shaft are combined into a single integral component, reducing the number of parts that need to be manufactured and assembled. This simplifies the manufacturing process and reduces device complexity while maintaining the functional requirements of both the shaft and tooth system.
Solution Approach 2:
The shaft is segmented into a hollow structure with an internal cavity, allowing for simplified manufacturing processes such as casting or forming. This segmentation enables easier production while reducing material usage and simplifying the overall component structure.
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
The design results in a lighter shaft module with reduced material consumption, facilitating lower CO2 emissions and cost-effective production, contributing to CO2 neutrality goals.
Implementation Method 1
The first tooth system and the hub are connected to each other by at least one welded joint
Data Source
AI summary
A shaft module at least having a first tooth system and at least two bearing seats is distinguished in that the first tooth system sits on a hub and is connected to the hub by at least one welded joint, and in that the bearing seats are formed on components separate from the tooth system. At least one of the components and the tooth system are secured on each other by a welded joint.