“Self-designed”—just four simple characters that represent a breakthrough achieved through countless hours of dedication and effort. It could be the loneliness and obscurity of years spent quietly pursuing scientific research; it could be repeated experimental failures; it could be tireless, day-and-night repetition... How to leverage technological breakthroughs as a driving force to enhance core technological competitiveness and build an innovation engine for enterprises—this EDO high-efficiency, compact, low-vibration eight-ball-track cage-type mobile joint development project for constant-velocity drive shafts has provided a brilliant answer. At the end of last year, the “Design Specifications for EDO-Type Cage-Type Universal Joints” were officially released and put into effect. Upholding the belief in self-designed innovation, the project’s development team faced no difficulties and set no limits, transforming what seemed impossible into what was truly achievable.

Pioneering standards, directly at the cutting edge of technology.

As automakers increasingly demand optimized space utilization, lightweight designs, and high efficiency, the EDO-type highly efficient, compact, low-vibration ball-joint CV joints have gained widespread adoption due to their smooth and reliable performance, large oscillation angles, substantial extension-retraction range, and excellent manufacturability. Currently, several “9+N” automakers are placing even higher demands on CV joint space, weight, oscillation angle, and travel distance, calling for the use of eight-ball-track CV joints. Meanwhile, a certain vehicle model supported by our company has been experiencing vibrations during acceleration from 60 to 80 km/h. After analysis, it was determined that the change in vehicle alignment angle from 6° to 8° resulted in an axial force exceeding 60 N on the inner ball cage at the 8° angle, thus failing to meet the vehicle’s operational requirements. Under this dual pressure, the urgent development of an EDO-type, highly efficient, compact, low-vibration eight-ball-track ball-joint CV joint has become imperative.

All efforts in scientific and technological innovation are geared toward the future. How to better grasp future trends, proactively plan and target key areas for research, and break through more critical technologies—this is the enduring conviction of every Wanxiang technical professional. The project team meticulously studied complex sets of data, carefully examined numerous potential solutions, and tackled one intricate experiment after another. After more than half a year of relentless effort, they finally succeeded in conquering this “tough challenge.”

Before the establishment of standards, project personnel had to conduct detailed measurements and mapping of similar products to support the development of mobile joints for customers’ new vehicle models, a process that was both time-consuming and labor-intensive. With the successful completion of this R&D effort, the design of mobile joint products now has standardized guidelines to follow. By simply inputting customer-specific parameter requirements—such as torque, limit speed, and power—engineers can directly proceed with the design, simulation analysis, and prototype development of comparable products. The entire process has been remarkably smooth and efficient.

The successful development of this project has filled a gap in the company’s product lineup, enabling us to offer large-arc and long-stroke products. It has also accumulated valuable experience for the subsequent processing of similar long-stroke, thin-walled, thick-section components. Moreover, this project played a crucial role in the mass production phase of a certain project undertaken by Company F, laying a solid foundation for securing designated supplier status for numerous “9+N” customers, including Company B and Company H. As of the end of May, the sales revenue from Company F’s project had reached nearly 10 million yuan.

Innovative breakthroughs: Mastering new technological tools.

In terms of product design, the customer had high requirements for the ball cage’s travel distance, swing angle, and spatial constraints. The project team broke free from the limitations of the original design, carefully studied all technical specifications, and achieved the following improvements in the new product: a 20% increase in travel distance, a 23% increase in maximum swing angle, a reduction in outer diameter, and a weight reduction of 15.7%.

In terms of process improvement, the inner spherical surface exhibited significant deviation from the coaxiality of the ball track due to deformation caused by heat treatment. However, this challenge did not stump the team of engineers, who boast extensive development experience. They quickly identified the solution: optimizing the process flow by adding a hard-turning operation for the inner spherical surface after the heat treatment step, thereby effectively controlling the runout coaxiality within 0.01 mm.

In terms of equipment improvements, the existing equipment was unable to machine workpieces that were excessively long. Therefore, the project team designed a new thin-base support rest, which raised the position of the workpiece. At the same time, a new machining program was developed, and the cutting tool’s approach angle during切入 was increased, thereby resolving the issue of insufficient machining stroke. Additionally, the tool design was refined, and a new vibration-resistant solid carbide milling cutter was manufactured specifically for processing the product.

In terms of tooling improvements, we’ve extended the clamping jaws and, without altering the clamping force, reduced the pressure at the clamping point to address deformation issues. We’ve also designed a new type of rigid milling fixture that uses elastic rubber to secure the ball-way head to the base, thereby resolving the issue of high scrap rates caused by positioning deviations.

Over countless days and nights, the project team went through numerous rounds of rejection and restarts. When the design couldn't achieve optimal results, they refined the solution; when the solution couldn't be implemented, they improved the equipment; and when the equipment couldn't produce the desired product, they sought out superior materials and more rational tooling... All those agonizing experiences of “rejection and restarts” ultimately became the gateway to their innovative breakthroughs. “We never hesitated or compromised,” said Wu Pingping, an engineer in the Product Development Department. “We always uphold the highest standards, unleash every innovation potential, and devote ourselves wholeheartedly to ensuring the success of each project.”

Overcoming challenges and demonstrating strong technical capabilities.

Innovation and breakthroughs never happen overnight; behind them lie the fearless confidence to confront challenges head-on and the unwavering determination to strive bravely toward the pinnacle of science and technology. “In the eyes of some people, technological innovation is painstaking and tedious—every design specification requires repeated experimentation and verification. But in my eyes, it’s actually quite fascinating. Through technological innovation, we overcome technical hurdles in developing new products and achieve greater cost reductions and efficiency improvements. That sense of joy and accomplishment is the best possible encouragement,” Wu Pingping said with a smile.

In the view of Zheng Dexin, head of the Product Development Department, what matters most for technical personnel is to stay true to their original aspirations and keep working diligently over the long term. He believes that the project team has indeed done just that: “This project marks the first time standards have been established for this type of product, making it highly significant. Especially during the early stages of project design, Wu Pingping had to collect a great deal of data. At the same time, he was also responsible for the product design of several related supporting projects, so his workload was exceptionally heavy. Yet he proactively worked overtime to complete data collection and organization—showing great responsibility and tremendous effort.”

Of course, the ultimate formation of a standardized procedure is by no means the result of just one person’s efforts. They’re a highly motivated team: “Avoiding tough problems altogether has never been our engineers’ style—‘Let’s think of another solution’ is a phrase that’s often on our lips.” In terms of scheme design, process improvement, and experimental verification, the project team has pooled its collective wisdom and energy. Late-night sessions lit by lamps, technical drawings spread across desks, and brainstorming sessions in conference rooms—many innovations have emerged precisely from these collaborative efforts.

Complex tasks are tackled simply; simple tasks are repeated diligently; and repetitive tasks are approached with innovation—this is the true essence of scientific and technological work. The vast number of Wanxiang’s science and technology professionals are deeply committed to the intricate details of technological innovation, steadfastly enduring the twists and turns—and sometimes even the intense challenges—of on-site processes, and calmly focusing on the multifaceted complexities of project research. With their “innovative solutions,” they address the questions posed by high-quality development, applying and promoting scientific and technological advancements in real-world enterprise production, thus contributing their own strength to the company’s continued growth and success!