Method and apparatus for detecting worn universal joint components

Abstract

A method and apparatus for detecting the operating condition of a universal joint in a driveline assembly utilizes a pressure relief valve that is supported by a universal joint cross member. The cross member includes a central body portion with a plurality of radially extending trunnions. A first driveline component supports a first yoke member and a second driveline component supports a second yoke member. Each yoke member cooperates with two opposing trunnions to interconnect the first and second driveline components. An internal lubrication channel is formed within the cross member and is in fluid communication with each trunnion. Seal assemblies are installed within cups mounted to each trunnion member to seal the lubricating fluid within the cross member. The universal joint is operating properly when lubricating fluid that is injected through an external lubrication fitting during service operations, exits via the pressure relief valve. The universal joint is not operating properly when the lubricating fluid exits via at least one of the seal assemblies instead of through the pressure relief valve.

1 - 16 . (canceled)  
   
   
       17 . A method for detecting an operating condition of a universal joint assembly comprising the steps of: 
 (a) injecting lubricating fluid into a cross member having a plurality of trunnions with seal assemblies coupled to first and second yoke members;    (b) detecting a properly operating universal joint when lubricating fluid exits a pressure relief member subsequent to step (a); and    (c) detecting an improperly operating universal joint when the lubricating fluid exits at least one of the seal assemblies subsequent to step (a).    
   
   
       18 . The method as set forth in  claim 17  wherein step (a) further includes generating an internal lubrication pressure in response to injecting lubricating fluid into the cross member via an external lubrication fitting; step (b) further includes activating the pressure relief member when the internal lubrication pressure exceeds a predetermined pressure value; and step (c) further includes having a predetermined initial sealing force for each seal assembly that is greater than the predetermined pressure value and detecting a worn universal joint component when the internal lubrication pressure is less than the predetermined pressure value and when the lubricating fluid exits at least one of the seal assemblies.  
   
   
       19 . The method as set forth in  claim 17  wherein step (a) further includes injecting the lubricating fluid into the cross member via an external lubrication fitting that is separate from the pressure relief member.  
   
   
       20 . The method as set forth in  claim 17  including providing the pressure relief member with a component that is movable relative to an external surface of the cross member; and wherein step (b) includes detecting the properly operating universal joint when the component moves from a first position where the component engages the external surface of the cross member to a second position where at least a portion of the component is moved out of engagement with the external surface.  
   
   
       21 . The method as set forth in  claim 20  wherein step (c) includes detecting the improperly operating universal joint when the component remains in the first position and the lubricating fluid exits at least one of the seal assemblies subsequent to step (a).  
   
   
       22 . The method as set forth in  claim 21  including resiliently biasing the component to remain in the first position by applying a predetermined force and detecting the properly operating universal joint during step (b) when the predetermined force is overcome as a result of performance of step (a).  
   
   
       23 . The method as set forth in  claim 17  including forming an internal lubrication channel within the cross member, fluidly connecting the internal lubrication channel to each trunnion of the plurality of trunnions via trunnion channel portions, mounting an external lubrication fitting to the cross member, fluidly connecting the external lubrication fitting to the internal lubrication channel via a first channel portion, and fluidly connecting the pressure relief member to the internal lubrication channel via a second channel portion.  
   
   
       24 . The method as set forth in  claim 23  wherein step (a) includes injecting the lubricating fluid into the first channel portion; step (b) includes detecting a properly operating universal joint when lubricating fluid exits the pressure relief member via the second channel portion; and step (c) includes detecting an improperly operating universal joint when lubricating fluid exits one of the seal assemblies via a respective trunnion channel portion.  
   
   
       25 . A method for detecting an operating condition of a universal joint assembly comprising the steps of: 
 (a) visually detecting a properly operating universal joint assembly when lubricating fluid exits a universal joint assembly from a first location; and    (b) visually detecting an improperly operating universal joint assembly when lubricating fluid exits the universal joint assembly from a second location different than the first location.    
   
   
       26 . The method as set forth in  claim 25  including defining the first location at a pressure relief member interface and defining the second location at a trunnion seal interface.  
   
   
       27 . The method as set forth in  claim 26  including providing the universal joint assembly with a cross member having a plurality of trunnions and an external lubrication fitting, forming an internal lubrication channel within the cross member, sealing each trunnion with a seal member, fluidly connecting the external lubrication fitting to the internal lubrication channel, and injecting lubricating fluid into the internal lubrication channel by way of the external lubrication fitting prior to an occurrence of at least one of step (a) and step (b).  
   
   
       28 . The method as set forth in  claim 27  including mounting the pressure relief member to the cross member, fluidly connecting the pressure relief member to the internal lubrication channel, and wherein step (a) includes visually detecting a properly operating universal joint assembly when lubricating fluid exits the pressure relief member and step (b) includes visually detecting an improperly operating universal joint assembly when lubricating fluid exits the seal member from at least one of the plurality of trunnions.