WO2014005584A1

WO2014005584A1 - Method for producing a propeller shaft from a fiber-plastic composite material, propeller shaft, and propeller shaft arrangement

Info

Publication number: WO2014005584A1
Application number: PCT/DE2013/100250
Authority: WO
Inventors: Oliver Fischer; Martina PANITZEK; Christoph Rüegg
Original assignee: Xperion Gmbh
Priority date: 2012-07-06
Filing date: 2013-07-05
Publication date: 2014-01-09

Abstract

The invention relates to a method for producing a propeller shaft (2), especially a universal joint, from a fiber-plastic composite material. According to said method, a tubular propeller shaft body (4) and a propeller yoke (5) arranged at the end of the propeller shaft body (4), said yoke being formed by a receiving device (8, 9) for a propeller element (10), is produced as a single piece by way of a filament winding process. The invention further relates to a propeller shaft and a propeller shaft arrangement.

Description

Method for producing a propeller shaft made of a fiber-plastic composite material, propeller shaft and cardan shaft arrangement

The invention relates to technologies in the field of propeller shafts.

background

Cardan shafts are usually used for the transmission of torques or rotational movements, be it for example in general mechanical engineering or especially in vehicle construction. In one embodiment, the propeller shaft has a tubular cardan shaft body on which at least one yoke is arranged, which is useful to produce a cardan shaft assembly in which the joint shaft is integrated in a joint, such that the joint with the inclusion of the yoke the cardan shaft body is arranged. For the purpose of weight reduction, it has been proposed to replace metallic propeller shafts by propeller shafts in which the tubular propeller shaft body consists of a fiber-plastic composite material (FKV, composite material). As fiber-plastic composite materials in particular carbon fiber reinforced plastic (CFRP) or glass fiber reinforced plastic (GRP) are used.

In the propeller shaft different types of joints can be integrated, which can for example also allow compensation of angular misalignment and / or axial misalignment in installation and operating condition. Cardan joints, rubber disc washers, constant velocity joints, multi-disc clutches and the like belong to the joint types in particular.

If the tubular cardan shaft body is made of a fiber-plastic composite material, then a particular challenge is to functionally produce the transition to the joint. If the joint to be integrated is made of metal, a change of the material takes place in the region of the connection of the joint to the tubular cardan shaft body, namely from the fiber-plastic composite material to the metal. In the document DE 30 07 896 AI a connection for fiber-plastic tubes, in particular hollow shafts of motor vehicles, is described, which deals with this problem. It is there provided with longitudinally toothed interference fit. A disadvantage of this technology is the need for an overlap region for the introduction of force between the tubular drive shaft body of the fiber-plastic composite material and the metallic connector, wherein due to the required joint pressure, a relatively high wall thickness of the metallic connector is necessary. This leads to a fairly high weight of the force introduction area. In addition, the production of a suitable interference fit due to low tolerances, the production of splines and the joining process with high forces is expensive. Due to the high local forces between the yoke on the tubular shaft body on the one hand and the articulated cross coupling thereto on the other hand, the joint forks in metallic joints, such as universal joints, a fairly high wall thickness and are correspondingly heavy. However, this metallic tubular cardan shaft body in a purely metallic cardan shaft requires only a much smaller wall thickness for torque transmission. In terms of manufacturing technology, this usually leads to drawn tubes and forged joint forks in series production, which are connected to one another by means of welding. For small series and individual pieces, the joint forks are also produced by machining from solid material. This is associated with high costs, especially for a forging tool but also for the machining and the joining process. Overall, metallic joint forks are relatively expensive components.

A weight reduction could be achieved by making the joint fork arranged on the tubular cardan shaft body of the cardan shaft of a fiber composite material. The document DE 10 2009 026 013 AI proposes in this connection, first to produce the yoke separately from the tubular cardan shaft body in the form of two fork halves. As a manufacturing method for the separate production of the two fork halves, the fiber winding technique and the pressing or injection process for producing a fiber composite material may be mentioned. The two fork halves are each designed as a fiber composite bending beam and then mounted with the aid of a clamping ring on the tubular cardan shaft body end. The manufacturing process requires a separate manufacturing of the tubular cardan shaft body on the one hand and the on the other hand, the steering fork on the other hand, which is also designed in several parts. The separately produced parts of the PTO shaft must then be joined together.

Summary of the invention

The object of the invention is to provide new technologies in the field of propeller shafts, which consist at least partially of a fiber-plastic composite material, with which an effort-reduced and more cost-effective production of propeller shafts is possible. In addition, the propeller shafts should have the lowest possible weight.

This object is achieved by a method for producing a propeller shaft, in particular universal joint, according to the independent claim 1. Furthermore, a propeller shaft according to the independent claim 8 and a propeller shaft assembly according to the independent claim 9 are provided. Advantageous embodiments of the invention are the subject of dependent subclaims.

It is a method for producing a propeller shaft, in particular universal joint shaft, provided from a fiber-plastic composite material, in which a tubular cardan shaft body and an end of the cardan shaft body arranged joint fork, which is formed with a receiving device for a joint element, are manufactured integrally by means of fiber winding method ,

According to a further aspect, a propeller shaft, in particular cardan shaft, made of a fiber-plastic composite material having a tubular Gelenkwellenkör- per and on the propeller shaft body end arranged yoke having a receiving device for a joint member, wherein the propeller shaft body and the yoke are designed as a one-piece, fiber-wound component.

Moreover, an articulated shaft arrangement with a propeller shaft, which has a tubular cardan shaft body and an articulated fork arranged at the end of the cardan shaft body, and a joint, which is formed with the participation of the joint fork, is such that one of the articulated arms arranged on the cardan shaft body fork associated articulated fork via a hinge element to a receiving device articulated, which is formed on the yoke, wherein the propeller shaft body and the yoke are designed as a one-piece, fiber-wound component. The use of the filament winding method, which is known as such in various embodiments and is also referred to as "filament winding", makes it possible to produce tubular cardan shaft body and joint yoke formed thereon in one operation, such that a one-piece, fiber-wound component is produced The one - piece production by means of fiber wounds makes it possible to produce a component in which the integration of the joint coupling in the form of the yoke into the propeller shaft on the shaft joint can be achieved by means of fiber - plastic composite material The result is a one-piece composite of tubular cardan shaft body on the one hand and yoke on the other, which defies high mechanical demands despite its low weight ren allows an individual adjustment of the manufacturing process to different types of propeller shafts, for example by selecting the used for winding fibers and / or the particular type of winding used the fibers. In particular, carbon fiber reinforced plastic materials can be used, but also glass fiber reinforced plastic materials can be used.

In contrast to the injection method, another advantage of the winding method is that the raw materials fiber and matrix resin are processed at low cost into a single component in one method step. In the injection process, a flat textile semi-finished product (fabric, scrim, mat) must first be produced in a first process step, which is then impregnated in a second process step by injection of the resin in the mold. The material costs are therefore significantly lower in the winding process. In addition, the fiber winding process does not require a multi-part tool, which causes high costs, but only a cylindrical winding core, the relatively simple and cost-effective. is inexpensive to manufacture. As a result, the total tool costs are significantly lower than in the injection or pressing process.

A preferred development provides that at the end, at least in the region of the joint gas, a material thickening is produced. By means of the material thickening, the direct transition from the tubular cardan shaft body into the end-side yoke can be carried out. The tubular cardan shaft body has a wall thickness corresponding to its function. In order to take into account the power transmission and the introduction of force in the area of the end joint yoke, a corresponding material thickening can be used. The material thickening can be carried out as a fiber-wound material thickening, which means that additional fibers are wound up in the region of the material thickening.

In an expedient refinement, it can be provided that fibers are wound locally in the peripheral direction during formation of the material thickening and / or textile semi-finished products are locally inserted. The insertion of textile semi-finished products can be used as an alternative or in addition to the fiber-wound in the circumferential direction material thickening. As textile semi-finished products, for example, tissue or so-called multiaxial scrims can be used.

An advantageous embodiment provides that the fiber-plastic composite material is post-processed after curing by machining. By means of machining, for example, edge processing can be carried out. But also the working out of recesses and / or breakthroughs can be provided.

Preferably, a training provides that the receiving device for the joint element is made with opposing pin bosses on the yoke. For example, the pin bosses are used for supporting a joint element, which is a spider, for example, a spider of a universal joint.

In an advantageous embodiment, provision may be made for recesses for engaging one of the joint yokes to be assigned in the area of the articulated fork arranged at the end. ten yoke are formed. In this embodiment, recesses are produced in the region of the end-side yoke of the articulated shaft and / or adjacent thereto, for example by means of subsequent machining, so as to produce a receiving space in which then engages a yoke which is the joint fork formed on the end of the joint body is assigned in the trainee joint, so cooperates with this in the joint via one or more the yokes coupling joint elements. For example, the recesses may be in the form of a semicircle or a semi-ellipse. A development may provide that the end-mounted joint fork is formed circumferentially closed. In this embodiment, the propeller shaft in the region of the end arranged joint fork is made circumferentially closed. So it just lacks recesses, which serve in the joint training the receiving the flange-side yoke. For example, such a hinged fork allows the inclusion of an asymmetric spider on the propeller shaft. The asymmetrical spider has crossed articulated arms of different lengths. The spider thus extends in one direction to a lesser extent than in the transverse direction thereto. However, in the respective direction extending from the center of the spider articulated arms are symmetrical in the respective direction to the center.

In conjunction with the propeller shaft and the propeller shaft arrangement, the foregoing statements apply accordingly with regard to advantageous embodiments.

In the propeller shaft assembly, the propeller shaft is integrally formed with a joint which is formed with the participation of the tubular cardan shaft end end arranged yoke, for example, such that a flange-side yoke via the joint member, for example, a spider, coupled to the yoke on the tubular cardan shaft body. The flange-side yoke is formed on a connecting flange of the joint, which preferably also consists of a fiber-plastic composite material. It can be provided that the connecting flange is designed with the flange-side yoke as a one-piece molded part. A one-piece joint component may be formed from a fiber-plastic composite material which has a joint fork arranged on one end section and a connecting flange arranged on an opposite end section. With the aid of the yoke, the one-piece joint component can be coupled to a coupling component of a joint, in particular a universal joint, so as to be integrated into the joint. On the other hand, the one-piece joint component can be connected via the connecting flange arranged on the opposite side to components or elements which are intended to couple to a joint. In that regard, the one-piece joint component may also be referred to as a flange-side joint component.

According to another aspect, a cardan shaft assembly is provided with the one-piece hinge member. In the propeller shaft assembly, a joint-shaft-side joint component is arranged on an axially extending propeller shaft end. This is coupled to a joint coupling element, for example a spider, which on the other hand couples to the flange-side joint component, so that the propeller shaft is provided with a joint, in particular a universal joint.

Furthermore, a method for producing a joint member is provided, wherein the joint member is made at one end portion with a yoke and an opposite end portion with a connecting flange and as an integral part of a fiber-plastic composite material.

A preferred embodiment provides a first component portion in which fibers of the fiber-plastic composite material have a first fiber orientation and a second component portions in which fibers of the fiber-plastic composite material have a second fiber orientation that is different from the first fiber orientation. The respective fiber orientation is expediently formed as a preferred orientation, in which a predominant proportion of the fibers, for example at least 50%, are aligned substantially in accordance with the preferred orientation. A possible fiber orientation is also characterized in that a random or disordered orientation of the fibers is formed in the component section. In this case, then preferably at least 50% of the fibers have a random orientation. In an expedient embodiment, a first composite material region, in which mainly fibers of a first type of fiber are arranged, and a second composite material region may be provided, in which predominantly fibers of a second type of fiber are arranged, which is different from the first type of fiber. The first and second types of fibers may differ in one or more fiber properties. This includes, for example, the material from which the fibers are made. For example, carbon fibers and glass fibers can be used. But also a variation in the thickness of fibers made of the same material can lead to the distinction of fiber types.

An advantageous embodiment provides that the first and the second type of fiber differ at least with regard to the fiber length. For example, on the one hand continuous fibers and on the other hand long fibers can be used as different types of fibers. In contrast to long fibers, continuous fibers are fibers with a length that extends over the entire structural length of the component. Long fibers may, for example, have a length between about 0.5 cm and about 5 cm.

Preferably, a further development provides that the first component section comprises an outer edge region of the joint fork and the second component section comprises an inner region of the joint fork. The inner region of the yoke may be provided with one or more apertures, which may also be referred to as a pin eye. The breakthrough serves, for example, the inclusion of a joint coupling component, in particular a spider. It can then be provided that fibers in the hole or eye near area have a preferred orientation in the radial direction.

In an advantageous embodiment it can be provided that the first composite material region comprises the outer edge region of the joint fork and the second composite material region the inner region of the joint fork. In one embodiment, predominantly or exclusively endless fiber strands are arranged in the outer edge region of the yoke. This makes it possible to form a loop-like reinforcement of the plastic material in the outer region. In the inner area of the yoke, for example around the Breakthrough around, long fibers are preferably introduced, which may have, for example, a random orientation.

A further development can provide that the joint component is designed as a fiber-plastic pressed component. In the production of the one-piece joint component, it may be provided to introduce a fiber-plastic molding compound into a molding tool in one or more press-molding steps and to apply pressure to the molding, for example using a stamp and / or a pressing component. In this case, provision can be made for fibers to be introduced into the mold cavity before the introduction of the fiber-plastic molding compound, which fibers then combine with the fiber-plastic molding compound.

In the process of producing the one-piece joint component, it is possible to rework the previously hardened molded part, for example by machining to introduce, for example, one or more openings, in particular holes, which results in the region of the joint fork as well as in the region of the flange connection Case can be. In the region of the yoke, one or more pin bosses can be created in this way, thereby creating a receiving device for a joint coupling part, for example a spider. One or more holes may be provided in the area of the flange connection so as to prepare the flange connection for a screw or bolt connection.

It may be provided a propeller shaft, which has an axially extending drive shaft body and a yoke, which is arranged on the end of the propeller shaft body. The cardan shaft body and the yoke are connected to one another via a rotationally locked connection, in which a shaft-body-side connecting element and a fork-side connecting element are connected to one another to form the connection. The shaft-body-side connecting element on the cardan shaft body and / or the fork-side connecting element on the yoke are formed as a fiber-plastic pressing element.

The propeller shaft can be produced by a method in which an axially extending cardan shaft body with a shaft body side connecting element and a yoke be provided with a fork-side connecting element. Cardan shaft body and yoke are then connected together by means of a rotational connection. In the rotational connection, the yoke is arranged end to the propeller shaft body. The shaft-body-side connecting element and the fork-side connecting element are connected to each other in forming the rotational connection. The shaft-body-side connecting element on the cardan shaft body and / or the fork-side connecting element on the yoke are manufactured by means of compression molding and curing of a fiber-plastic molding compound as a fiber-plastic pressing element. It can be provided that the shaft-body-side connecting element and the fork-side connecting element are slidably connected relative to each other in the axial direction, so that, for example, for operational propeller shaft length change, an axial relative movement between the joint fork and the cardan shaft body is made possible. The PTO shaft described herein may be used in the PTO shaft assembly discussed above.

In the following, further aspects of the propeller shaft, in which the propeller shaft body and the yoke are connected via a rotational connection, and their production are explained.

The rotational connection between the cardan shaft body and the yoke means, in particular, that a rotational movement of the cardan shaft body or yoke forces the co-rotation of the other joint member to transmit a torsional moment. Different materials can be used for the cardan shaft body, including in particular metallic materials or fiber-plastic composite materials. The cardan shaft body is executable as a tubular body.

The shaft-body-side connecting element is preferably produced on an outer surface of the cardan shaft body and then cooperates with a fork-side connecting element which is produced on the inside of the yoke. But also a reverse Training can be provided, in which then the fork-side connecting element is made on an outer surface.

A preferred development provides that both the shaft body-side connecting element on the cardan shaft body and the fork-side connecting element on the yoke are formed as a fiber-plastic pressing element. To form the fiber-plastic pressing element, a fiber-plastic molding compound is used in the various embodiments, in which one or more types of fibers are embedded in a moldable plastic material, which cures after the press molding on the respective associated component. For example, carbon fibers and / or glass fibers can be used as fibers. Preferably, the distribution of the fibers in the plastic mass is random.

It can be provided that the shaft-body-side connecting element and the fork-side connecting element are displaceable relative to each other in the rotational connection in the axial direction, so that an axial relative movement between the joint fork and the cardan shaft body is made possible. In this way - when overcoming the connecting elements in the respective relative position to each other securing connection force, which is essentially determined by frictional forces, - allows axial relative movement between yoke and propeller shaft body, for example, for purposes of assembly and / or operational propeller shaft length change. The rotationally locked connection between the cardan shaft body and the yoke is designed in this embodiment such that upon occurrence of forces exceeding a constructionally adjustable limit force, the cardan shaft body and yoke are displaced relative to each other in the axial direction, so that the length of the propeller shaft changes. This makes it possible that the PTO shaft flexibly adapts in terms of their length to restrictions during installation and / or to the operating conditions in each case.

In an expedient embodiment, it can be provided that the shaft-body-side connecting element and the fork-side connecting element are provided on mutually associated surfaces with mutually corresponding and at least partially engaged surface structures. In one embodiment, the surface structures are formed with a respective tooth structure, wherein extending or interrupted toothed webs preferably extend in the axial direction of the propeller shaft body. It can be provided that the surface structuring on the cardan shaft body and / or on the yoke on the respective surface are made circumferentially.

An advantageous embodiment provides that the rotational connection is made to form one or more centering aids. It may be provided that the one or more centering aids, which may be formed on the cardan shaft body and / or the yoke, circumferentially execute.

Preferably, a further development provides that the cardan shaft body consists of a fiber-plastic composite material. In one embodiment, the cardan shaft body is embodied as a fiber-wound body, for example a tube reinforced with carbon fibers and / or glass fibers.

In an advantageous embodiment can be provided that the yoke consists of a fiber-plastic composite material.

In an expedient embodiment, it may be provided that the shaft-body-side connecting element and / or the fork-side connecting element has, at least in sections, a sliding layer on a surface facing the other connecting element.

In connection with the method for producing the propeller shaft, the embodiments described above may be provided accordingly.

It can be provided, in the propeller shaft, the opposite end in one piece with a yoke. Description of preferred embodiments

Hereinafter, preferred embodiments will be explained with reference to figures of a drawing. Hereby show:

1 is a perspective view of a portion of a propeller shaft assembly with a propeller shaft and a joint formed thereon,

2 is a schematic representation of the portion of the propeller shaft assembly of FIG. 1 from the front,

3 is a schematic sectional view of the portion of the Gelenkwellenano- rrnung from FIGS. 1 and 2,

4 shows a schematic sectional view along a sectional plane through a joint element embodied as a symmetrical spider in the case of the cardan shaft arrangement from FIGS. 1 and 2,

5 shows a perspective illustration of a section of a further articulated shaft arrangement with a propeller shaft and a joint formed thereon with an outbreak for better visibility of the spider, FIG. 6 a schematic representation of the section of the further propeller shaft arrangement from FIG. 5 from the front,

7 shows a schematic sectional illustration of the section of the further articulated shaft arrangement from FIGS. 5 and 6,

8 shows a schematic sectional illustration along a sectional plane through a joint element embodied as an asymmetric spider in the case of the further cardan shaft arrangement from FIGS. 5 and 6,

9 is a schematic representation of a hinge component made of a fiber-plastic composite material from the front,

10 is a schematic representation of the joint component of FIG. 9 from above,

11 shows a schematic illustration of a method for producing the joint component from FIGS. 9 and 10, wherein a preforming tool for preforming is shown with a stamping tool,

Fig. 12 is a further schematic representation of the method for producing the

Joint component, wherein a preformed fiber-plastic molding compound is introduced in the preforming tool, a further schematic representation of the method for producing the joint component, wherein the fiber-plastic molding compound is preformed, another schematic representation of the method for producing the joint component, wherein a non-preformed fiber-plastic molding compound is introduced in the preforming tool,

1 is a further schematic representation of the method for producing the joint component, wherein a preform for the joint component is shown, a further schematic representation of the method for producing the joint component, wherein the preform is introduced in a further pressing tool,

a further schematic representation of the method for producing the joint component, wherein a semifinished product is shown,

FIG. 2 shows another schematic representation of the method for producing the joint component, wherein the joint component produced by means of finishing from the semifinished product in FIG. 17 is shown, FIG.

2 shows a further schematic illustration of the method for producing the joint component, wherein a further illustration of the semifinished product from FIG. 17 is shown, FIG.

a schematic representation of a portion of a drive shaft body from the front and from the side,

a schematic representation of the portion of the propeller shaft body of Figure 20 from the front and from the side, wherein for forming a wave-body-side connecting element, a fiber-plastic molding compound is applied.

a schematic representation of the portion of the cardan shaft body of FIG. 21 from the front and from the side, wherein for forming the shaft body side connecting element is a multi-part mold is shown, a schematic representation of the portion of the cardan shaft body of FIG. 22 from the front and from the side the removal of the multi-part mold,

schematic representations of an arrangement with a winding core and a shell arranged thereon from the front and from the side, 25a and b show schematic representations of the arrangement from FIGS. 24a and 24b, wherein a fiber-plastic molding compound is applied in the region of the molding shell,

Fig. 26a and b are schematic representations of the arrangement of Fig. 25a and 25b, wherein a

Traglaminat is applied by means of fiber wounds,

Figures 27a and b are schematic representations of the arrangement of Figures 26a and 26b from the front and from the side, wherein local reinforcements are formed by means of fiber coils,

28 is a schematic representation of the arrangement of FIG. 27b from the side, with the winding core and the mold shell being removed, FIG. 29 is a schematic representation of a joint fork, FIG.

Fig. 30 is a schematic representation of a portion of a propeller shaft with the tubular cardan shaft body, on the end of the yoke is arranged, and

FIG. 31 shows a schematic illustration of a section of the cardan shaft arrangement from FIG. 30 in a section along a line AA 'in FIG. 30.

Fig. 1 shows a perspective view of a portion of a propeller shaft assembly 1 with a propeller shaft 2, on which a hinge 3 is arranged, which is formed in the illustrated embodiment as a universal joint. The propeller shaft 2 has a tubular cardan shaft body 4, on the end of which a yoke 5 in the region of a material thickening 6 is produced. In the area of material thickening 6, the propeller shaft 2 has an increased wall thickness, whereby a direct and gradual transition 7 between the tubular prop shaft body 2 and the end material thickening 6 is produced. The propeller shaft 2 with the tubular propeller shaft 4 and the yoke 5 is integrally manufactured by means of fiber winding. Filament winding methods are known as such in various embodiments. To produce the tubular cardan shaft body 4, a winding method with a classic laying eye or with a ring thread eye can be used. The end material thickening 6 can be produced in the winding process with a conventional laying eye or by means of an additional device on the winding machine, with which the band-shaped semi-finished textile products can be wound up. Preferably, carbon fibers are used in the winding process. But also the at least partial use of glass fibers can be provided. The material thickening 6 can be produced by means of additional fiber windings and / or by inserting fibers and / or textile semi-finished products in the local region of the material thickening 6.

In the embodiment in Fig. 1, the yoke 5 has two pin bosses 8, 9 which are arranged opposite to each other and receive a joint element 10 designed as a spider. About the hinge member 10, the yoke 5 coupled to one of these associated yoke 1 1, which is connected to a connecting flange 12. In that regard, it is in the associated yoke 1 1 to a flange-side yoke. The associated joint fork 11 also couples to the spider 10, so that the joint fork 5 and the associated joint fork 11 are articulated via the joint member 10 to form the joint.

To accommodate the associated yoke 1 1 5 recesses 13, 14 are made in the region of the material thickening 6 adjacent to the yoke fork. The production of the recesses 13, 14 takes place, for example, by means of subsequent machining of the semifinished product previously produced by means of the fiber winding method.

2 and 3 show the portion of the propeller shaft assembly 1 of FIG. 1 from the front and in section. 4 shows a sectional view along a sectional plane through the joint element 10 designed as a spider. It follows that joint element arms 10a, 10b have the same length and are each arranged symmetrically to the center of the joint element 10. This embodiment can also be referred to as a symmetrical joint element, whereby then a symmetrical joint is attached to the propeller shaft 2.

In contrast to this, FIGS. 5 to 8 show an embodiment in which the articulated-element arms 10a, 10b are in each case also arranged symmetrically with respect to the center of the articulated element 10, but of different length (compare in particular FIG. 8). It is made as an asymmetric joint element, resulting in an asymmetric joint on the steering shaft 2 leads. In this embodiment, the propeller shaft 2 is then circumferentially in the region of the material thickening 6 free from the recesses 13, 14 (see Fig. 1). Their training is not necessary due to the unequal lengths of the joint element arms 10a, 10b. It is so the mechanical stability of the propeller shaft 2 in the region of the thickening 6 is not affected by the recesses 13, 14th

With reference to FIGS. 9 to 19, a hinge component 20 and a method for its production from a fiber-plastic composite material will be described below. The articulated component 20 can be used in the articulated shaft arrangements described above as the component with the associated yoke 11 and the flange 12 connected thereto. But it can also be provided that to use the joint component in conjunction with other propeller shafts, such as propeller shafts, which consist wholly or partly of metal. For example, with cardan shafts that have a tubular cardan shaft body made of fiber-reinforced plastic material and a metal yoke. But also the use of a completely made of metal propeller shaft can be provided, which then couples the joint member 20 via one or more joint elements. FIGS. 9 and 10 show the hinge component 20 from the front and from above. A yoke 21 is integrally connected via a transition region 22 with a flange 23. The yoke 21 has an eye portion 24 in which two pin bosses 25, 26 are made. The pin bosses 25, 26 serve, for example, for receiving a spider, as described above in connection with the embodiments in FIGS. 1 to 8.

The manufacture of the joint component 20 from a fiber-plastic composite material will be described below with reference to FIGS. 11 to 18. According to FIG. 11, a preforming tool 30 having a cavity 31 is provided, into which endless fiber strands 32 impregnated with matrix resin are inserted and subsequently consolidated by means of a punch 33, in particular preformed. This is then in the cavity 31 a fiber-plastic molding compound 34 introduced and consolidated by means of a pressing tool 35, which is shown schematically in Figs. 12 and 14. The fiber-plastic molding compound 34 contains long fibers in a moldable plastic compound. Here, according to FIG. 13, it is possible to preform the fiber-plastic molding compound 34 in an intermediate step in an auxiliary tool 36 by means of an auxiliary punch 37 and then the preformed fiber-plastic molding compound 34 in the cavity 31 of the preforming tool 30 to bring. In the embodiment of FIG. 14, the fiber-plastic molding compound 34 is not preformed in this form. In this way, a preform 38 for the joint component 20 according to FIG. 15 has now been produced. The preform 38 has areas 39 in which endless fiber strands are embedded in the plastic material, as well as areas 40 with the long fibers of the fiber-plastic molding compound 34. The continuous fibers 32 extend in particular in the edge region of the joint fork of the joint component 20 to be formed.

In the further method, the preform 38 is introduced as shown in FIG. 16 in a further pressing tool 41 with a lower part 42, which provides a cavity 43, and acted upon by means of an upper part 44 with pressing pressure. This results in a semifinished product 45 according to FIG. 17, which is subsequently machined to produce the joint component 20 according to FIG. 18. In this case, the flange 23 is provided with bores 46, which serve to form a Flanschver gland.

FIG. 19 shows a further illustration of the semifinished product 45 from FIG. 17, wherein the regions with endless fibers 39 and the regions with long fibers 40 are shown schematically. The future bolt eye 26 is indicated by means of a dash-dot line. In the region of an edge 47 of the future stud eye 26, a proportion of the total embedded fiber amount of at least about 30% is provided, in which the fibers do not deviate more than about +/- 20 ° from the radial direction of the future stud boss 26. The joint component 20 represents an advantageous development for several reasons. With its help, there is also a flange-side part of a joint of fiber-plastic composite material. The hinge member 20 increases the bearing fatigue strength by another Fiber orientation in the area of the edge of the hole by the hole is introduced only after the shaping and the fibers are intentionally cut through this. It is by means of simple, inexpensive, easily automatable manufacturing processes. A loop-like fiber orientation around a pin bore results in only low bearing strength when the fiber loop is not laterally supported. Such lateral support is in a yoke of fiber-plastic composite material, in particular CFRP, but not possible or at least not appropriate to produce. In order to achieve a much higher bearing fatigue and fatigue strength, it has been proposed here to arrange a considerable proportion of the fibers radially outward from the edge of the bore. Good bearing strength thus already reach laminates, which have many different fiber orientations when the hole is machined.

The hinge member 20 is therefore pierced only after the forming process and has many different fiber orientations in the vicinity of the bore, at least about 30% of which deviates by no more than about + / - 20 ° from the radial direction. This is conveniently and inexpensively achieved by using a long fiber reinforced molding compound with random fiber orientation in the vicinity of the later bore. This material selection is combined with endless fiber strands, which form a loop-like reinforcement only in the outer area of the eye, but not in the vicinity of the bore. In the transition region between the outer region and the vicinity of the bore, a gradual, harmonic transition of the fiber orientation from the endless fiber strands in the outer region to the random fiber orientation of the long fibers in the bore region is formed by the preforming technique used and by the flow processes during the pressing (see FIG. 19). This achieves both a high flexural strength of the eye area and a high bearing fatigue strength.

The other areas of the joint component 20 preferably also have a random (involuntary) fiber orientation and are thus inexpensive to manufacture without complex measures to ensure any prescribed (arbitrary) fiber orientation. The somewhat lower rigidity and strength values of a long-fiber-reinforced molding compound than continuous-fiber-reinforced laminates can be compensated by a suitable geometric design with slightly increased wall thicknesses. The low density compared to steel fiber-plastic composite material used then still leads to a lightweight component, but in contrast to a continuous fiber reinforced component can be made much cheaper and easier to automate.

Hereinafter, with reference to FIGS. 20 et seq., A propeller shaft, in particular universal joint shaft, and a method for manufacturing will be described in which an axially extending propeller shaft body is connected via a rotational connection to a yoke, which is arranged on the end of a cardan shaft body.

FIGS. 20 to 23 are schematic views for describing a method of manufacturing a cardan shaft body 50 which is manufactured in the embodiment shown as a tubular cardan shaft body. 20, the cardan shaft body 50 is first made of a fiber-plastic composite material by means of fiber coils on a winding core 51. Filament winding processes, which are also referred to as "filament winding" in embodiments, are known as such in various embodiments.

According to FIG. 21, a fiber-plastic molding compound 52 is then applied to the produced cardan shaft body 50. The fiber-plastic molding compound 52 comprises a moldable plastic material in which fibers are randomly distributed, for example glass fibers and / or carbon fibers.

Then, as shown in FIG. 22, a die shell 53, which is multi-piece in the illustrated embodiment and has an inner tooth structure 53a, is applied to produce a shaft-body-side connecting member 54 having a surface structure 55 by the fiber-plastic molding compound 52. In the embodiment shown in FIG. 23, the surface structure 55 has a toothing 56 and a centering section 57. The toothing 56 has outwardly projecting teeth or toothed webs and recesses formed between them which extend in the axial direction of the cardan shaft body 50 extend. The cardan shaft body 50 is then cured with mounted mold shell 53. After curing, the winding core 51 is pulled out (not yet shown in FIG. 23) and the mold shell 53 is removed in the radial or axial direction. As a result, the cardan shaft body 50 is formed with the integrally formed shaft body-side connecting element 54, which has the centering section 57.

Figs. 24 to 29 show schematic representations in connection with a yoke and their preparation. In this case, according to FIGS. 24a and 24b, an arrangement is provided with a winding core 60 and a molded shell 61 mounted thereon. The mold shell 61 has a negative surface structure 62 with a toothing 62a and a centering seat 62b. The mold shell 61 is mirror-symmetric with respect to the negative surface structure 62.

In the following, according to FIGS. 25 a and 25 b, a fiber-plastic molding compound 63 is applied in the area of the molding shell 61 and adjacently thereto and processed with the aid of a contour putty 64. Then, one or more layers of a supporting laminate 65 are applied by means of fiber winding method, which schematically show FIGS. 26a and 26b.

As shown in FIGS. 27a and 27b, local reinforcing regions 66, 67 are then wrapped / wrapped on and / or between the individual layers of the supporting laminate 65, likewise by means of fiber winding processes, the wound fibers being embedded in a conventional manner in a plastic material.

After curing, the winding core 60 with the mold shell 61 is then separated from the component made of the fiber-plastic composite material according to FIG. 28. By means of piercing in this case a pole cap 68 is removed. In the embodiment shown, the components formed mirror-symmetrically on the mold shell 61 are separated in a comparable manner. To produce a yoke 69, which is shown schematically in FIG. 29, recesses 70 are then produced in the illustrated embodiment, preferably by means of machining. Also bores 71 for receiving a joint element forth- provided, in particular for the connection of a spider. In an alternative embodiment, the recess 70 may also be omitted, as has been described comparable above in connection with FIGS. 5 to 8. The yoke 69 shown in FIG. 29 has a fork-side connecting element 72, which in the embodiment shown is formed with an internally encircling toothing whose surface structure is embossed by the shell 61.

30 shows a schematic representation of a section of a propeller shaft in which the articulated fork 69 is now pushed onto the cardan shaft body 50 on the end in such a way that the shaft-body-side connecting element 54 and the fork-side connecting element 72 are in engagement to form a rotationally locked connection. This means in the described embodiment that the mutually associated toothings at least partially interlock.

According to FIG. 30, a liquid filling compound 74 is provided for forming a sliding layer via an opening 73, which deposits in a cavity 75 between the surface of the fork-side connecting element 72 and the shaft-body-side connecting element 54 and then solidifies. The filling compound 74 may preferably be a thermosetting or a thermoplastic plastic. In order to maintain the desired tolerances and to achieve a seal, in this case a centering aid 76 is inserted, which centered the cardan shaft body 50 to the yoke 69 fork side and which is removed after the solidification of the filling material 74 again. A centering is also shaft body side by the pressed-centering 57th

Overall, this arrangement provides an arrangement in which the yoke 69 is centered end mounted on the propeller shaft 50, wherein by means of the rotational connection, which is formed by means of the shaft body side and the fork-side connecting element 54, 72 and the solidified filling material 74, a backlash-free axial Relative movement between the propeller shaft 50 and the yoke 69 is made possible, so that the propeller shaft during operation, if appropriate forces occur, can change their length. Such a relative movement does not occur until attacking forces have exceeded a limit force. stride. Below the limit force cardan shaft body 50 and yoke 69 are secured against unintentional slipping. The rotational connection of the connection is ensured in the illustrated embodiment by means of the engagement of the toothings on the shaft body-side connecting element 54 and on the fork-side connecting element 72.

In order to support adhesion of the filling compound 74 introduced via the opening 73 for forming the sliding layer in the surface region of at least one of the joining partners, for example on the surface of the fork-side connecting element 72, it may be provided to activate the surface regions to be coated, for example by means of radiation treatment. len, chemical activation and / or the use of a primer. Additionally or alternatively, it may be provided to deactivate the surface regions of the other joining partner, for example the surface of the shaft body-side connecting element 54 for which adhesion of the filling compound 74 is not desired, for example by applying a release agent or a release wax and / or or the use of oil or grease in these surface areas.

In the foregoing, production of the fork-side connecting member 72 and the shaft-body-side connecting member 54 on a respective cardan shaft member has been exemplified, which itself consists of a fiber-plastic composite material. Without further ado it follows that the connecting elements produced as fiber-plastic press components can be formed in a comparable manner also on joint components made of other materials, which consist for example of metal. Thus, it may be provided to produce the shaft body-side connecting element on a tubular metal shaft body.

The PTO shaft can be combined with other PTO shaft technologies described above. For example, it may be provided to make the propeller shaft in one piece in the opposite end region, as has been explained above, for example, with reference to FIGS. 1 to 8. The features of the invention disclosed in the above description, the claims and the drawings may be of importance both individually and in any combination for the realization of the invention in its various embodiments.

Claims

claims

Method for producing a propeller shaft (2), in particular universal joint shaft, of a fiber-plastic composite material in which a tubular cardan shaft body (4) and an articulated fork (5) arranged at the end of the cardan shaft body (4) and connected to a receiving device (8, 9) for a joint element (10) is formed integrally by means of fiber winding process.

A method according to claim 1, characterized in that at the end, at least in the region of the yoke (5) a material thickening (6) is produced.

A method according to claim 2, characterized in that in the formation of the material thickening (6) fibers in the circumferential direction and / or semi-finished textile products are placed locally.

Method according to at least one of the preceding claims, characterized in that the fiber-plastic composite material is post-processed after curing by machining.

Method according to at least one of the preceding claims, characterized in that on the yoke (5) the receiving device for the joint element (10) with opposite pin bosses (8, 9) is produced.

Method according to at least one of the preceding claims, characterized in that recesses (13, 14) for engaging a joint fork (5) associated with joint fork (11) are formed in the region of the end arranged joint fork (5).

Method according to at least one of claims 1 to 5, characterized in that the ends arranged joint fork (5) is formed circumferentially closed.

Cardan shaft (2), in particular universal joint shaft, made of a fiber-plastic composite material, with a tubular cardan shaft body (4) and one at the hinge shaft The articulated fork (5) is arranged at the end and forms a joint element with a receiving device (8, 9) for a joint element (10), the tubular cardan shaft body (4) and the yoke (5) being integral , fiber-wound component are executed.

9. cardan shaft assembly (1), with

- A propeller shaft (2), which has a tubular cardan shaft body (4) and one on the propeller shaft body (4) end arranged joint fork (5), and

- A joint (3), which is formed with the participation of the yoke (5), such that one of the tubular shaft body (2) end arranged joint fork (5) associated yoke (11) via a hinge member (10) to a receiving device (8, 9) hingedly coupled to the yoke (5) is formed, wherein the tubular cardan shaft body (4) and the yoke (5) are designed as a one-piece, fiber-wound component.

10. Cardan shaft assembly (1) according to claim 9, characterized in that the associated yoke (11) is designed as a flange-side yoke, which is integrally formed on a connecting flange (12).

11. Cardan shaft assembly (1) according to claim 10, characterized in that the connecting flange (12) with the flange-side yoke made of a fiber-plastic composite material.

12. cardan shaft assembly (1) according to claim 11, characterized in that the connecting flange (12) with the flange-side yoke is designed as a one-piece, fiber-wound flange.

13. Cardan shaft assembly (1) according to at least one of claims 9 to 11, characterized in that the connecting flange (12) with the flange-side yoke (11) is designed as a one-piece press-formed component (20).