Abstract: A noise and vibration damper for use with a rotatable structure, such as a driveshaft assembly for a vehicular drive train system, includes an inner member, an elastomeric member that extends about the inner member, and an outer member that extends about the elastomeric member. The inner member is formed from a sheet of material that has been deformed to a desired shape, while the outer member is formed from a tube of material having a length that is selected to provide the desired dampening frequency. The natural resonant frequency of the noise and vibration damper can be adjusted by varying either or both of the shape of the inner member or the axial length of the outer member of the noise and vibration damper. In both instances, the weight distribution of the components of the noise and vibration damper is altered.

Abstract: A method of manufacturing a tube for a vehicle driveshaft assembly forms a flat sheet of material having a greater thickness than other portions over a portion of its width and along its length, rolling the sheet about a longitudinal axis such that its lateral edges are mutually adjacent, then securing the lateral edges together by seam welding to form a tube. The mass distribution is not uniform because the wall thickness of certain portions of the tube is greater than the wall thickness of other portions of the tube. A tube yoke is machined and the angular location of its overbalance about its longitudinal axis is determined. The tube is secured to the tube yoke such that the angular location of overbalance of the yoke is aligned with the weld seam and diametrically opposite the region of the tube having the greater wall thickness.

Abstract: A vehicle drive train assembly includes a source of rotational power and at least one rotatably driven vehicle wheel. A male splined member and a female splined member are connected between the source of rotational power and the vehicle wheel to transmit rotational power therebetween. At least one of the splined members is a driveshaft. The splines of the male splined member have side surfaces and outer surfaces which are convex in shape. The convex splines of the male splined member cooperate with the splines of the female splined member to connect the splined members together in a manner that allows for limited angular and axial movement therebetween.

Abstract: A universal joint assembly includes a cross and an end fitting having respective rotational centers that are precisely co-axially aligned with one another to minimize rotational imbalance. The cross has a pair of outwardly extending trunnions, upon which respective bearing cups are rotatably supported. A span control sleeve is press fit about each of the bearing cups. Each of the span control sleeves includes an outwardly extending flange portion that is precisely located relative to the rotational center of the cross. The end fitting is formed having a pair of inwardly facing surfaces that are precisely located relative to the rotational center of the end fitting. When the cross is assembled with the end fitting, the outwardly extending flange portions of the span control sleeves abut the inwardly facing surfaces of the end fitting. As a result, the rotational center of the cross is precisely aligned with the rotational center of the end fitting.

Abstract: A method for manufacturing a driveshaft assembly takes advantage of the asymmetrical nature of the driveshaft tube and end fittings to reduce the initial imbalance of the driveshaft assembly. The method includes the initial steps of providing a driveshaft tube having a heavy side and providing an end fitting having a heavy side. The heavy side of the end fitting is aligned so as to be opposite the heavy side of the driveshaft tube. Finally, the driveshaft tube and the end fitting are secured together. The dimensional characteristics of the driveshaft tube and end fitting improve the balancing capability of the driveshaft assembly by permitting levels of imbalance of the driveshaft assembly to be lowered and better-managed.

Abstract: A universal joint assembly includes a cross and an end fitting having respective rotational centers that are precisely co-axially aligned with one another to minimize rotational imbalance. The cross has a pair of outwardly extending trunnions, upon which respective bearing cups are rotatably supported. A span control sleeve is press fit about each of the bearing cups. Each of the span control sleeves includes an outwardly extending flange portion that is precisely located relative to the rotational center of the cross. The end fitting is formed having a pair of inwardly facing surfaces that are precisely located relative to the rotational center of the end fitting. When the cross is assembled with the end fitting, the outwardly extending flange portions of the span control sleeves abut the inwardly facing surfaces of the end fitting. As a result, the rotational center of the cross is precisely aligned with the rotational center of the end fitting.

Abstract: An improved female splined member includes a female tubular member having an inner surface provided with a plurality of longitudinally extending grooves that are sized and spaced in accordance with a desired number and position of splines to be formed. A plurality of elongate rods is disposed in respective longitudinally extending grooves formed in the inner surface of the female tubular member. A quantity of positioning material is provided within spaces provided between the elongate rods and the longitudinally extending grooves. The positioning material is hardened to support the elongate rods in the longitudinally extending grooves to define a plurality of inwardly extending splines in the female splined member. An improved method for manufacturing a female splined member includes the initial step of providing a female tubular member having an inner surface provided with a plurality of circumferentially spaced, longitudinally extending grooves.

Abstract: A noise and vibration damper for use with a rotatable structure, such as a driveshaft assembly for a vehicular drive train system, includes an inner member, an elastomeric member that extends about the inner member, and an outer member that extends about the elastomeric member. The inner member is formed from a sheet of material that has been deformed to a desired shape, while the outer member is formed from a tube of material having a length that is selected to provide the desired dampening frequency. The natural resonant frequency of the noise and vibration damper can be adjusted by varying either or both of the shape of the inner member or the axial length of the outer member of the noise and vibration damper. In both instances, the weight distribution of the components of the noise and vibration damper is altered.

Abstract: An improved female splined member includes a female tubular member having an inner surface provided with a plurality of longitudinally extending grooves that are sized and spaced in accordance with a desired number and position of splines to be formed. A plurality of elongate rods is disposed in respective longitudinally extending grooves formed in the inner surface of the female tubular member. A quantity of positioning material is provided within spaces provided between the elongate rods and the longitudinally extending grooves. The positioning material is hardened to support the elongate rods in the longitudinally extending grooves to define a plurality of inwardly extending splines in the female splined member. An improved method for manufacturing a female splined member includes the initial step of providing a female tubular member having an inner surface provided with a plurality of circumferentially spaced, longitudinally extending grooves.

Abstract: A method for manufacturing a splined member, such as a male or female splined shaft, having a low friction coating applied thereto includes the initial step of providing a length of cylindrical stock having a predetermined outer diameter. The end of the cylindrical stock is then machined by any conventional process to form a preform including an end portion and a neck portion. Next, the end portion of the preform is subjected to a cold working process by a conventional roll forming machine or similar tool to form a plurality of splines about the circumference thereof. The cold working process is effective to re-shape the end portion of the preform to form the splines without the removal of any material therefrom. As a result, each of the splines is formed having a generally involute cross sectional shape, wherein opposed sides of the splines are relatively gently curved between the inner roots and the outer ends thereof.

Abstract: A vehicle drive train assembly includes a source of rotational power and at least one rotatably driven vehicle wheel. A male splined member and a female splined member are connected between the source of rotational power and the vehicle wheel to transmit rotational power therebetween. At least one of the splined members is a driveshaft. The splines of the male splined member have side surfaces and outer surfaces which are convex in shape. The convex splines of the male splined member cooperate with the splines of the female splined member to connect the splined members together in a manner that allows for limited angular and axial movement therebetween.

Abstract: An apparatus for quickly and efficiently balancing an article includes a pair of supports that are adapted to engage and support the ends of the driveshaft tube and to effect selective rotational and axial movement thereof. A system is provided for generating a representation of the shape of the outer surface of the driveshaft tube, such as by using a laser stripe generator and a digital camera. The laser stripe generator projects a relatively thin line of visible light onto the outer surface of the driveshaft tube. The digital camera receives the relatively thin visible line of light as it is reflected from the outer surface of the driveshaft tube and digitizes the reflected image into electrical signals. The apparatus further includes a system for generating a representation of the wall thickness of the driveshaft tube, such as by using an ultrasonic transducer.

Abstract: A driveshaft assembly for use in a drive train system includes an inner driveshaft tube section including an end portion having an outer surface and an outer driveshaft tube section including an end portion having an inner surface. A plurality of axially extending wires is positioned on either the outer surface of the inner driveshaft tube section or on the inner surface of the outer driveshaft tube section. Then, the end portion of the outer driveshaft tube section is disposed about the end portion of the inner driveshaft tube section so as to define an overlapped region therebetween. At least one of the end portions of the inner and outer driveshaft tube sections is then deformed so as to compress the wires therebetween. As a result, recesses are formed in the outer surface of the inner driveshaft tube section and in the inner surface of the outer driveshaft tube section.

Abstract: A slip yoke assembly includes a slip yoke having a barrel portion extending from a first end to a second end and a lug portion extending from the first end thereof. The barrel portion has a bore extending from the first end to the second end. The bore has a splined inner surface. The slip yoke assembly also includes a plug having a flange portion. The flange portion is attached to the first end of the barrel portion of the slip yoke. The plug also has a body portion which extends from the flange portion a predetermined distance into the bore. The slip yoke assembly also includes a shaft having an end portion disposed inside the bore of the slip yoke. The end portion includes an end which abuts the body portion of the plug. The end portion of the shaft has a splined outer surface which cooperates with the splined inner surface of the slip yoke bore to provide a rotatable connection between the shaft and the slip yoke while allowing a limited amount of relative axial movement therebetween.

Abstract: A noise reduction structure for an aluminum-based driveshaft tube includes a generally cylindrical member having a predetermined length. The noise reduction structure is disposed within a driveshaft tube in a press fit relationship with the inner surface of the tube. In general, the noise reduction structure is positioned within the driveshaft tube at a location where the amplitude of a standing wave caused by the reflection of the sound waves back and forth along the driveshaft tube is at its maximum value. The length of the noise reduction structure may be about 10% or less of the value of the length of the driveshaft tube. In a first embodiment, the noise reduction structure is formed from a polymeric foam material having a density of less than about 10 lb/ft3. Preferably, the material has a density in the range of about 2 lb/ft3 to 10 lb/ft3, and more preferably, in the range of about 3 lb/ft3 to 7 lb/ft3.

Abstract: A half round end yoke and a pair of retainer straps retain an opposed pair of bearing cups to the half round end yoke in such a universal joint. The half round end yoke includes a body defining an axis of rotation having first and second arms extending therefrom. Each of the first and second arms has a semi-cylindrical recess formed therein that is adapted to receive a bearing cup. A pair of threaded bores is formed in each of the first and second arms. Retainer straps are disposed about the bearing cups to retain them within the semi-cylindrical recesses. Each of the retainer straps includes a curved central portion having a pair of straight end portions extending outwardly therefrom. The end portions have respective apertures formed therethrough that can be aligned with the threaded bores formed in the arms of the half round end yoke.

Abstract: A telescoping driveshaft assembly that has a relatively low collapse force rating and that does not have a reduced torque carrying capacity includes an inner tube that is received within an outer tube in a press fit relationship. The inner tube is disposed within the outer tube such that a predetermined amount of overlap is formed between the two tubes. A mechanical interlock is formed in the overlapped region for increasing the total frictional force between the inner tube and the outer tube as well as for increasing the torque carrying capacity of the driveshaft tube. The mechanical interlock can be formed using one or more crimps which are disposed in the overlapped region. The length of the overlapped region, the number of crimps and the crimp configuration are a function of a number of factors including the torque requirements of the driveshaft tube, the sizes of the inner tube and the outer tube, and the material chosen for the driveshaft tube.

Abstract: A method of manufacturing a drive line assembly includes the initial step of providing a driveshaft tube formed from a metallic material and having a substantially uniform wall thickness. The driveshaft tube terminates in an axially extending cylindrical end portion. Then, a diameter reducing portion is provided that is formed from a metallic material and has a substantially uniform wall thickness. The diameter reducing portion includes an axially extending cylindrical first end which is co-axial with and permanently fixed to the axially extending cylindrical end portion of the driveshaft tube. The diameter reducing portion further includes an axially extending cylindrical second end. The axially extending cylindrical first end of the diameter reducing portion defines a first diameter, and the axially extending cylindrical second end of the diameter reducing portion defines a second diameter. The first diameter is larger than the second diameter.

Abstract: A method for forming an enlarged diameter aluminum alloy driveshaft tube having an interior reduced diameter portion that avoids clearance issues with respect to other components of the vehicle includes the initial step of providing a tube of aluminum alloy material having a diameter that corresponds to the enlarged diameter of the driveshaft tube to be formed. Then, a determination is made as to whether any component of the vehicle is located sufficiently close to the driveshaft tube to interfere with the rotation thereof during normal operation. If so, the position and axial length of the potential interference is located on the aluminum alloy tube. A diameter reducing process is then performed on the aluminum alloy tube to form the interior reduced diameter portion to eliminate the potential interference.

Abstract: A noise reduction structure for a vehicle driveshaft assembly insures that each of the interior chambers of the driveshaft tube is properly vented during use. The noise reduction structure is a solid member having a predetermined length and a cross sectional shape which corresponds generally to the cross sectional shape of the driveshaft tube. Preferably, the noise reduction structure has an outer diameter which is approximately equal to, or slightly larger than, the inner diameter of the driveshaft tube. As such, the noise reduction structure engages the inner surface of the driveshaft tube in a light press fit relationship. Each noise reduction structure has a passageway, groove, or other opening formed therein which extends axially throughout its length. In a preferred embodiment, an axially-extending groove is formed on the outer circumferential surface of the noise reduction structure.