Wheel Module Hub Spacer for Torque Transmission and Contamination Protection
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Solution Overview
Problem
Current motor vehicle wheel modules with serrations require a massive drive shaft component to transmit torque, leading to increased weight and material usage, and are vulnerable to dirt and moisture ingress due to the design.
Innovation Solution
A wheel module design featuring a wheel hub with end face toothing engaging a mating toothing on the drive shaft, utilizing a spacer element between the wheel bearing and drive shaft to secure the wheel bearing position and protect the toothing regions from contamination, allowing for a separate wheel hub and bearing configuration that reduces weight and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a massive drive shaft component with serrations is used to transmit torque, then torque transmission is achieved, but weight and material usage increase
Solution Approach 1:
The invention divides the drive shaft into two separate components: a lighter shaft portion and a separate hub portion with toothing. The hub portion is attached to the shaft portion, allowing torque transmission while significantly reducing the weight of the rotating mass. This segmentation enables the use of lower-grade materials for the shaft while maintaining high-grade steel only where necessary for the bearing and toothing interfaces.
Solution Approach 2:
The invention applies high-grade steel material properties locally only to the hub portion and bearing areas where high strength and wear resistance are critical for torque transmission and rolling contact. The shaft portion can use lower-grade, lighter materials since it primarily serves as a non-rotating torque carrier. This localized quality optimization reduces overall weight while maintaining necessary performance.
2Power
If serrations are used for torque transmission, then torque is transmitted, but the design is vulnerable to dirt and moisture ingress
Solution Approach 1:
The invention extracts the toothing interface from the traditional serration design embedded within the shaft bore. Instead, the hub portion with external toothing is mounted on the shaft, creating a sealed interface where the toothing engages with a corresponding toothing on the shaft flange. This external mounting approach allows for better sealing and protection against dirt and moisture ingress while maintaining effective torque transmission through the toothing engagement.
3Strength
If high-grade steel is used for the entire wheel hub and drive shaft, then strength and durability are improved, but cost increases
Solution Approach 1:
The invention segments the wheel hub assembly into components that can be manufactured separately with different material grades. The shaft portion can be manufactured from lower-cost materials, while the hub portion with bearing interfaces uses high-grade steel. This segmentation allows for cost-effective manufacturing while maintaining necessary strength and durability in critical areas.
Solution Approach 2:
The invention applies high-grade steel material properties locally only to the hub portion and bearing areas where high strength and wear resistance are critical for torque transmission and rolling contact. The shaft portion can use lower-grade, lighter materials since it primarily serves as a non-rotating torque carrier. This localized quality optimization reduces overall cost while maintaining necessary performance.
4Device complexity
If the wheel bearing is mounted directly on the drive shaft, then assembly is simplified, but the toothing regions are exposed to contamination
Solution Approach 1:
The invention introduces the hub portion as an intermediary component between the drive shaft and the wheel bearing. The hub portion includes the toothing interface that engages with the shaft and provides the mounting surface for the bearing. This intermediary structure protects the toothing regions from direct exposure to contamination while maintaining a relatively simple assembly process, as the hub portion can be pre-assembled with the bearing before mounting to the shaft.
Data Source
AI summary
A wheel module for a motor vehicle, the wheel module including a wheel carrier, a wheel hub, a wheel bearing separate from the wheel hub that supports the wheel hub on the wheel carrier, and a drive shaft for driving the wheel hub. The wheel hub having end face toothing engaging a mating toothing on the drive shaft. A spacer element is arranged axially between the wheel bearing and the drive shaft wherein the spacer element adjoins the end face toothing and/or the mating toothing radially on the outside.