Fiber winding specialist Dynexa has developed a concept output shaft with shaft tubes made of carbon-fiber-reinforced plastic, allowing it to be directly compared to metal competitors.
In vehicle testing, the prototype size and manufacturing of Dynexa withstood the toughest tests. The results and findings obtained caught the attention of the testers.
Installation space: Due to the forced suspension stroke, the installation space is sufficient. This facilitates the size and design of the new Dynexa "composite output shaft", which is suitable for fiber composite materials.
Torque transmission: The output shaft of Dynexa in the vehicle is also convincing here, and it is in no way inferior to the metal competition in transmissions up to 3000 Nm.
Vibration characteristics at speed: The speed characteristics and vibration characteristics in the torsional and bending directions proved to be good and problem-free.
Weight: Shock absorbers that are absolutely necessary to eliminate metal competition help reduce weight: they don't have to be "pulled" by the Dynexa shaft as extra weight. If a perfectly suitable Dynexa interference fit is used to transfer torque from the two connecting elements to the fiber composite shaft tube, the metal hub overlaps the two fiber composite tube ends inside. The joint pressure required for torque transmission places additional stress on the part compared to solid metal solutions that are usually welded, and requires a local support ring that overlaps the outer diameter of the tube. Despite the need for these additional components compared to solid metal technology, and the relatively short carbon fiber reinforced shaft tube has a diameter of approx. 250 mm.
During the electrification of vehicles, there are different engine concepts and variations for power transmission. However, compared to conventional vehicles with internal combustion engines, the limitation of range remains a huge challenge. In addition to the performance capacity of the battery storage unit, the lowest possible vehicle weight is the maximum adjustment screw for the much-needed range improvement. It is uncertain which drive concepts will prevail in the future. But one thing is certain: With the help of the new lightweight output shaft, even in the short term, Dynexa can and can contribute to the future of global mobility.