Dana Corporation

Dana Automotive Systems Group, LLC

Torque-Traction Technologies, Inc.

Johnny Neal Smith

Thomas M O'Neil

Jeffrey A Dutkiewicz

Albert Aiken

Eric M Fischer

James A Duggan

Boris A Yablochnikov

Robert G Joyner

Damien Gremillard

Jeffrey Allan Dutkiewicz

In a first embodiment, at a time of magnetic pulse welding, a stepped tube profile machining process axially bores a walled tube from an end inward to a transition depth to form a section with a reduced wall thickness and then axially bores the walled tube from the transition depth to a fall off depth, thereby forming a section with a maximized welding wall section. In a second embodiment, also at a time of magnetic pulse welding, a surface angle tube profile machining process axially bores at a surface angle a walled tube from an end to a bore length to form an angular welding wall thickness inward to a maximized wall section. For both embodiments, the bored surfaces are virgin with no pits, oil, residue, or oxidation thereon, thus making the machined walled tubes available for immediate magnetic pulse welding.

Tube profile machining process

A method of forming a sliding spline-type joint using magnetic pulse forming technology includes providing a female driveshaft member and a splined insert having inwardly formed splines. A male driveshaft member is provided having outwardly formed splines engageable with the insert. A mandrel is provided having outer ribs similar to the outer spline profile of the male driveshaft member. An inductor is provided which is energized to create a pulse magnetic field. The insert is placed over the mandrel. The female driveshaft member is disposed over the insert, and both are placed inside the inductor. The inductor is energized to deform a portion of the female driveshaft member over the insert to form an array of crimps for permanently connecting the female driveshaft member with the insert. The male driveshaft member is engaged into the insert to provide a sliding spline-type of slip joint.

Magnetic pulse formed vehicle driveshaft and method of making same

A driveshaft assembly having a tubular shaft, an end component, and an annular anti-fretting spacer is disclosed. The tubular shaft has a first receiving end portion with an opening and an inner diameter, a center portion with an inner diameter, and an interior with an inner surface. The driveshaft end component has an insert end portion and an attachment end portion. The spacer has a first outer diameter that is substantially equal to the receiving end portion inner diameter, a second outer diameter, and an outer surface. At least a portion of the outer surface contacts the shaft inner surface and the spacer is disposed on the insert end portion of the driveshaft end component and the insert end portion, including the spacer, is disposed within the receiving end portion with an interference fit, and the shaft is rigidly coupled to the driveshaft end component.

Spacer for a driveshaft assembly

An axially adjustable driveshaft assembly in a drive train system is described. Two hollow driveshaft sections, where one has a valve through an aperture in it and each has an end fitting, engage each other to form an axially adjustable driveshaft assembly that has a sealed internal chamber within. When a pressurized air or vacuum source is connected to the valve, air fills the chamber or air is removed from the chamber, which correspondingly increases or decreases a drive train system length. This results in facilitating the installation of the driveshaft assembly between a transmission and an axle assembly in a drive train system.

Axially adjustable driveshaft assembly

A slip joint comprising, a female portion comprised of four axially extending segments. The segments together create an outer perimeter. Each of the combined segments together form an inner surface of the female portion and each has its own ball tracks extending substantially the length of the female portion. A unitary male portion has an outer surface defined by a plurality of axially extending ball tracks. A unitary cage is located radially outward from the male portion and radially inward from the female portion. The cage has a plurality of ball apertures with balls located in the ball apertures. The balls are in contact with both the ball tracks in the male and female portions for selective movement of the male portion with respect to the female portion. A tube member is in direct radial outer contact substantially entirely along the outer perimeter of the female portion.

Slip joint and method for assembling the same

A method of installing an axially adjustable driveshaft assembly in a drive train system is described. Two hollow driveshaft sections, where one has a valve through an aperture in it and each has an end fitting, engage each other to form an axially adjustable driveshaft assembly that has a sealed internal chamber within. When a pressurized air or vacuum source is connected to the valve, air fills the chamber or air is removed from the chamber, which correspondingly increases or decreases a drive train system length. This results in facilitating the installation of the driveshaft assembly between a transmission and an axle assembly in a drive train system.

Method of installing axially adjustable driveshaft assembly

A center bearing assembly has an adjustable pneumatic support member for absorbing vibrations. The bearing assembly includes a bearing and a support member assembly that supports the bearing. The support member assembly includes a bladder having an interior chamber that is filled with a fluid. A bracket is provided that supports the support member assembly for pivoting movement relative thereto. A system is provided for controlling the magnitude of the fluid pressure within the interior chamber of the bladder. The system includes a plurality of sensors that generate signals that are representative of a plurality of operating conditions. A controller is responsive to the sensor signals and generates a signal to a pressure regulating device that controls the magnitude of the fluid pressure within the interior chamber of the bladder.

Center bearing assembly having an adjustable pneumatic support member

A journal cross includes a trunnion having a lubricant passageways formed therethrough. A retainer is disposed in the lubricant passageway and includes a body portion and a lip portion. The body portion of the retainer is retained within the lubricant passageway in a press fit relationship, and the lip portion of the retainer extends inwardly into the lubricant passageway. The bearing cup includes a thrust washer that is retained therein by needle bearings and a seal assembly. The thrust washer includes a projection that extends radially inwardly within the lubricant passageway and has one or more fingers provided thereon. When the bearing cup is installed on the trunnion, the fingers of the thrust washer cooperate with the lip portion of the retainer to retain the bearing cup on the trunnion, such as during shipment from one manufacturing location to another.

Retainer for universal joint bearing cups

A cross for use in a universal joint includes a lubrication system for positively causing lubricant to flow into the region of the bearings contained within a bearing cup mounted on the trunnion. The lubrication system includes a pump that is disposed in the lubrication passageway formed in the trunnion of the cross. In a first embodiment, the pump is embodied as a reciprocating piston pump, including a hollow cylindrical housing having a piston slidably supported therein. When the cross is rotated during use, the piston is moved radially outwardly relative to the housing, thereby injecting a quantity of lubricant from the lubricant passageway into the region of the bearings. When the cross is ceased to be rotated, the piston is moved radially outwardly relative to the housing under the urging of a spring. In a second embodiment, the pump is embodied as a rotatable auger pump. When the bearing cup rotates back and forth relative to the trunnion during use, the auger is rotated relative to the housing, thereby causing lubricant to be pumped from the lubricant passageway into the region of the bearings.

Lubrication system for a universal joint cross

A slip joint, such as for use in a vehicular driveshaft assembly, includes a first member having a plurality of male splines provided thereon and a second member having a plurality of female splines provided thereon. The male splines cooperate with the female splines so as to connect the first and second members together for concurrent rotational movement and for relative axial movement. A wedge member is disposed between portions of the first and second members to take up looseness therebetween and to adjustably control the amount of force that is required to be exerted in order to effect relative axial movement. The wedge member includes a body portion having a plurality of leg portions extending therefrom. The wedge member is positioned such that the leg portions are received within an annular space between the first and second members. A cap can be provided for facilitating the positioning of the wedge member relative to the first and second members and for retaining the wedge member in a desired position relative to the two members. The cap can be threaded onto one of the members such that rotation of the cap causes the cap and the wedge member to move axially relative to the first and second members.

Slip joint for vehicle driveshaft assembly

A cross for a universal joint in a vehicle driveshaft assembly is comprised of a hollowed block of material having four openings. The hollowed block holds an inner cross that has a first cross member and a second cross member. Each cross member has an end portion that extends through a thrust bearing, and each thrust bearing is engaged with an opening in the hollowed block. The resulting thrust bearing joint can operate at higher loads than conventional cross designs.

Precision thrust bearing joint

A locking cover is designed to protectively enclose a lubricant fitting mounted on a cross of a universal joint and cannot be removed after installation without damaging or destroying the locking cover. The locking cover includes a first half and a second half that are joined together by a hinge. Each half includes a generally U-shaped body portion defined by a central web and a pair of opposed leg portions. The first leg has an outwardly extending tang formed thereon having an outwardly extending barb. The second leg has an opening formed therein that terminates in a shoulder. A cover panel extends between the first and second legs defining a partial cavity therebetween. A pair of posts are provided on the cover panel and extend inwardly into the partial cavity defined by the first and second legs and the cover panel. When the locking cover is closed about the lubrication fitting, the tangs are received within the openings such that the barbs engage the associated shoulders. As a result, the two halves are locked together about the lubricant fitting. The posts are sized and positioned to engage portions of the lubricant fitting to support the locking cover thereon. Once the two halves are enclosed about the lubricant fitting, the locking cover cannot be subsequently removed without damaging or destroying the locking cover. This feature prevents service personnel from readily gaining access to the lubricant fitting to lubricate the cross at premature intervals.

Locking cover for a lubrication fitting mounted on a universal joint cross

A seal assembly and seal guard are provided for a bearing cup positioned on a trunnion of a universal joint. The seal assembly includes a support ring and an elastomeric seal. The support ring is generally L-shaped in cross section, having a lower radial flange that is connected to an axial portion. The axial portion of the support ring is press fit within an inner bearing surface of the bearing cup. The support ring flange extends radially outwardly adjacent the open end of the bearing cup. The elastomeric seal is disposed within the support ring axial portion. An annular elastomeric seal guard is removably secured to the seal assembly. The seal guard is generally funnel shaped. The seal guard has an upper body with an annular interior groove. The interior groove has a diameter slightly larger than the diameter of the support ring flange. Thus, the seal guard can be secured to the support ring flange. The seal guard has a lower body inclined radially inwardly from the upper body. The lower body has an interior annular sealing surface. The seal guard interior sealing surface defines an inner diameter that is smaller than a diameter of a outer sealing surface along the circumference of the trunnion of the universal joint. When the bearing cup is installed on the trunnion, the seal guard engages the trunnion in a light press fit. The press fit establishes a lubrication chamber. The lubrication chamber is bordered by the trunnion, elastomeric seal, and seal guard. When filled with grease, the lubrication chamber provides a waterproof compartment to keep moisture away from the seal assembly.

Seal assembly and seal guard for a universal joint

An apparatus is disclosed for positioning a bearing cup with respect to a universal joint having a yoke. The apparatus includes a base. A support is connected to the base and disposed at a distance therefrom. A spacer connects the support to the base and fixes the distance. A ram is mounted on the support. The ram is movable relative to the support and toward the base. Movement of the ram is adapted for positioning the bearing cup with respect to the yoke.

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Toledo, OH, United States of America

Johnny Neal Smith