Novel double-deck Rzeppa constant velocity joint with large operating angle: Mechanism configuration and kinematic characteristics analysis

Abstract

Considering existing Rzeppa joints’ small operating angle, this research aims to explore a new ball-cage joint mechanism configuration with large operating angle while preserving Rzeppa joints’ kinematic characteristics, yielding novel double-deck Rzeppa constant velocity joints (DR-CVJs). An integrated coupling design method for a series kinematic chain of two Rzeppa joints is proposed, and a new ball-cage joint initial configuration is established. By introducing a constraint branch, a single mapping between input and output is established, and the novel DR-CVJ mechanism configuration with large operating angle is constructed. The degree-of-freedom properties of the DR-CVJ mechanism are assessed using the screw theory. The maximum operating angle’s constraint conditions of the DR-CVJ mechanism are given, and its working space is drawn. The kinematic solution of the DR-CVJ mechanism is obtained, and kinematic simulations are performed. The results show that the principle of the novel DR-CVJ mechanism configuration is feasible, its effective maximum operating angle can reach 60°, its kinematic characteristics are consistent with those of the existing Rzeppa joints, and the proposed DR-CVJ mechanism configuration has engineering development potential.