Wheel Spindle Drive Element Torque Transmission
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Solution Overview
Problem
Existing wheel disconnect systems in four-wheel drive vehicles face inefficiencies due to axial retention issues and torque transmission limitations, particularly when disengaging wheels from the drive train, leading to potential shock loads and reduced efficiency.
Innovation Solution
A wheel spindle drive element with cutting or forming elements on its inner diameter that displaces material to create a high-torque transmission joint with the spindle, allowing for precise assembly and zero clearance between mating components, enhancing torque transmission and tolerance zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional splined engagement elements are used with clearance between mating members, then assembly is easier with standard tolerances, but shock loads occur under changing torque input and torque transmission capability is limited
Solution Approach 1:
The cutting elements perform material displacement and groove formation on the spindle surface before final assembly is completed. This preliminary action creates interlocking features that eliminate the need for tight clearance tolerances between mating members, as the material displacement creates a positive mechanical engagement that compensates for normal manufacturing variations.
Solution Approach 2:
The invention converts the potential harm of material removal (which could create clearance and play) into a benefit by using the displaced material to form interlocking grooves and ridges. The material that is cut or displaced from the spindle outer surface is used to create engagement features that positively lock the drive element to the spindle, transforming what would be a defect (material removal creating clearance) into a strength-enhancing feature.
2Reliability
If an axial retention mechanism such as a nut or flange is used to prevent the drive element from sliding off, then axial retention is improved, but device complexity and assembly steps increase
Solution Approach 1:
The invention merges the torque transmission function and the axial retention function into a single integrated feature. The material displacement creates grooves and ridges that simultaneously transmit torque and prevent axial sliding of the drive element. This eliminates the need for separate retention mechanisms like nuts or flanges, as the interlocking grooves perform both functions concurrently.
Solution Approach 2:
The invention extracts and eliminates unnecessary components (axial retention mechanisms such as nuts, flanges, or separate locking features) by incorporating the retention function directly into the torque transmission interface. The material-displaced grooves themselves serve as the retention feature, removing redundant parts and simplifying the overall assembly.
3Strength
If closely controlled dimensional characteristics are used on mating members to prevent clearance, then torque transmission is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The cutting elements perform material displacement to create grooves and ridges that establish positive mechanical engagement before final assembly. This preliminary material shaping creates inherent mechanical interlocking that maintains torque transmission capability without requiring tight dimensional tolerances on the mating surfaces, as the interlocking grooves compensate for normal manufacturing variations.
Solution Approach 2:
The invention changes the engagement mechanism from relying on precise dimensional parameters (clearance fits, tolerance zones) to relying on material-displaced geometric features (grooves and ridges). This parameter change transforms the basis of torque transmission from dimensional precision to form geometry, which is more tolerant of manufacturing variations and easier to produce with standard machining processes.
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 solution enables improved torque transmission and reduced manufacturing complexity by creating a stronger interface with expanded tolerance zones, effectively addressing axial retention and efficiency issues in wheel disconnect systems.
Implementation Method 1
The wheel spindle drive element pressing onto an outer diameter of a spindle, displacing material by cutting or forming, to produce a joint with high torque transmission characteristics
Data Source
AI summary
A wheel spindle drive element for a wheel disconnect system. The wheel spindle assembling onto an outer diameter of a spindle, displacing material to form a joint with high torque transmission characteristics.