Spacing disc

Abstract

A spacing disc consisting of at least one additively deposited material (3, 5), the spacing disc (1) having a non-linear load-deflection curve (K).

Description

[0001] tuning disc

[0002] The invention relates to a tuning disc.

[0003] These shims, often also called adjustment washers, are used wherever precise adjustment of distances between two adjacent components or components mounted against each other is required, for example, to compensate for tolerances. These shims are manufactured in large quantities and with very fine dimensional increments, and are sorted according to the required gap size for the application. A shim is typically an annular disc body that is generally mounted with a relatively high preload to cover the entire temperature range over which the corresponding assembly operates.It is known to manufacture such tuning discs from a suitably dimensioned sheet of metal, i.e., by stamping, or, as described in US 10 139 808 B2, to manufacture them additively by 3D metal printing, whereby, since the tuning disc is formed from very thin layers deposited on top of each other during printing, the corresponding desired disc thicknesses can be produced very precisely.

[0004] The invention is based on the problem of providing an improved tuning disc.

[0005] To solve the problem, a tuning disc is provided according to the invention, consisting of at least one additively deposited material, wherein the tuning disc has a non-linear spring characteristic.

[0006] The tuning disc according to the invention is manufactured using an additive metal deposition process, for example, by 3D printing. It consists of at least one material, i.e., a metal or a metal alloy, but can also be a multi-layered component, for example, made of two or more layers of different metals or metal alloys. A characteristic feature is that the tuning disc exhibits a non-linear spring characteristic. This means that, under a corresponding force application and thus a corresponding elastic deformation of the tuning disc, the spring characteristic deviates from a straight line. Such a non-linear spring characteristic allows for a specific response to the actual load requirements and geometric conditions. A particular advantage is that, since the tuning disc is made of an additively deposited material, the spring characteristic or stiffness characteristic can be adjusted almost arbitrarily.Furthermore, additive manufacturing allows for optimal design of the thickness of the tuning disc, as well as the adaptation and reduction of material usage as much as possible.

[0007] The non-linear spring characteristic can be designed in various ways. It is conceivable that the spring characteristic curve has at least two linear sections with different slopes. Such a characteristic curve shape can be achieved, for example, by using two different materials or by incorporating different geometries within the disc cross-section, such as by introducing cavities or similar features.

[0008] Alternatively, the spring characteristic curve could have at least one section with a progressive slope, or at least one section with a degressive slope, or at least one section with a progressive slope and at least one section with a degressive slope. The spring characteristic curve can therefore exhibit almost any shape over the spring travel. For example, it could initially be linear at the start of force application and become flatter (progressive) or steeper (degressive) with increasing force application or degree of deformation. Similarly, with appropriate design, both a progressive and a degressive section, and possibly even a linear section, could be incorporated.Such a characteristic curve can also be achieved either by using two different materials, or possibly more than two different materials, or by different geometries across the disc's cross-section, or both. According to a first embodiment of the invention, the tuning disc can consist of only one material and have a geometry that defines an axial spring deflection with a non-linear spring characteristic when a force is applied. Thus, if the tuning disc is made of only one metal or metal alloy, the variation of the spring characteristic is achieved via the cross-sectional geometry.

[0009] Alternatively, it is conceivable that the tuning disc consists of at least two different materials and has a geometry that defines an axial spring deflection with a non-linear spring characteristic when a force is applied. Here, the different material choices and the geometry work together to adjust the spring characteristic accordingly. The different materials have different hardnesses; one is somewhat softer, the other somewhat harder, resulting in different spring constants. If a suitable geometry is superimposed on this, the spring characteristic can be further influenced.

[0010] It is conceivable, for example, that the tuning disc is designed in the manner of a disc spring assembly. It therefore has two or more angled sections relative to each other, as is known from a disc spring assembly, whereby these sections, viewed radially, can be of equal or different widths, and whereby, if more than two are provided, the sections are always at the same angle to each other, or the angles vary across the disc thickness. Such a tuning disc designed in the manner of a disc spring assembly can be made of just one material, or of two or more materials.

[0011] Alternatively, the tuning disc could have one or more cavities, and such a cavity design is conceivable for tuning discs made of a single material as well as for those made of two or more different materials. The tuning disc thus has a cross-section in which one or more axially or radially adjacent cavities are provided. If the tuning disc consists of two different materials, these cavities can be located in only one material or in both materials. Again, this allows for considerable freedom of variation in both the geometric and material design, coupled with a wide range of variations in the spring characteristic.

[0012] When cavities are introduced using additive manufacturing, they are advantageously designed to run closed in the circumferential direction of the disk. However, instead of one or more closed cavities, it is also conceivable to incorporate, for example, one or more radially open cavities. Such geometries can be produced as desired using 3D printing. This also allows one or more cavities to be used as cooling channels, which essentially run around the inside of the disk and can be permeated by a cooling fluid via corresponding openings. Temperature equalization can also occur through these channels, which in turn leads to a change in prestress.

[0013] When two materials are used, it is conceivable that they are arranged axially one behind the other, relative to the direction of force application. The two materials (the same applies, of course, if a third or fourth material is used) are thus, axially speaking, deposited on top of each other and arranged one behind the other. Under load, the force consequently acts on both or all materials. For example, the softer material can compress first. Once it essentially reaches its limit, the harder material can then compress, thus creating, for example, a spring characteristic with two consecutive linear sections with different slopes, if the sections are designed as simple ring segments. Naturally, it is also conceivable in such a case to superimpose a corresponding spring geometry.

[0014] Alternatively, it is conceivable that the two materials are arranged radially next to each other with respect to a force direction, and that one material protrudes axially beyond the other. In this case, the disc section made of one material protrudes slightly axially beyond the disc section made of the other material, so that when a force is applied, the protruding material is initially loaded and deflects. Once a certain degree of deformation is reached, the load is then applied to both materials, leading to a corresponding change in the spring characteristic.

[0015] The invention is explained below with reference to exemplary embodiments and the drawings. The drawings are schematic representations and show:

[0016] Figure 1 shows a schematic representation of a tuning disc of a first embodiment according to the invention, made of two different materials, one of which, viewed axially, forms a section that projects further forward than the other.

[0017] Figure 2 shows a schematic representation of the spring characteristic curve of the tuning disc from Figure 1.

[0018] Figure 3 shows a schematic representation of a tuning disc of a second embodiment according to the invention, made of two different materials arranged axially one behind the other and each having a cavity.

[0019] Figure 4 shows a schematic representation of the spring characteristic curve of the tuning disc from Figure 3.

[0020] Figure 5 shows a schematic representation of a tuning disc of a third embodiment according to the invention, made of a material in the form of a disc spring assembly.

[0021] Figure 6 shows a schematic representation of the spring characteristic curve of the tuning disc made of Fi Figure 7 shows a schematic representation of a tuning disc of a fourth embodiment according to the invention, made of two different materials in the form of a disc spring assembly.

[0022] Figure 8 shows a schematic representation of the spring characteristic curve of the tuning disc from Figure ?,

[0023] Figure 9 shows a schematic representation of a tuning disc of a fifth embodiment according to the invention, made of a material in the form of a disc spring assembly with a changing diameter.

[0024] Figure 10 shows a schematic representation of the spring characteristic curve of the tuning disc from Figure 9.

[0025] Figure 11 shows a schematic representation of a tuning disc of a sixth embodiment according to the invention, made of two materials in the form of a disc spring assembly with a changing diameter.

[0026] Figure 12 shows a schematic representation of the spring characteristic curve of the tuning disc from Figure 11.

[0027] Figure 13 shows a schematic representation of a tuning disc of a seventh embodiment according to the invention, made of a material with several axially arranged cavities.

[0028] Figure 14 shows a schematic representation of the spring characteristic curve of the tuning disc from Figure 13.

[0029] Figure 15 shows a schematic representation of an eighth embodiment of a tuning disc according to the invention, made of two materials with several axially arranged cavities, and Figure 16 shows a schematic representation of the spring characteristic of the tuning disc from Figure 15.

[0030] The following describes various different embodiments of different tuning discs, although it should be noted at this point that these are only a few selected examples; the invention is by no means limited to these. Rather, any other designs and variations are conceivable. The same reference numerals are used for comparable components wherever possible.

[0031] Figure 1 shows a schematic representation of a tuning disc 1 of a first embodiment according to the invention. This consists of an outer, annular section 2 made of a first material 3 and a radially inner second section 4 made of a second material 5. The materials 3 and 5 can be metals or metal alloys. The materials are additively deposited, i.e., the tuning disc 1 was manufactured, for example, using a 3D metal printing process. The radially inner section 4 can be seen projecting slightly beyond the radially outer section 2 when viewed axially.In the case of axial force application, i.e., when the tuning disc 2 is installed between two components to be spaced apart, an axial force is initially applied first to the inner section 4, which, for example, is made of a slightly softer material than the outer section 2. This results in the spring constant of the material 5 of the inner section 4 being smaller or significantly smaller than the spring constant of the material 3 of the outer section 2. Therefore, when a force is applied, the inner, axially projecting section 4 deforms first, until it deforms sufficiently that the force also acts on the radially outer section 2. Both sections are then loaded and deformed accordingly.

[0032] Figure 2 shows, by way of example, a characteristic curve of such a tuning disc. The force F is shown along the abscissa, for example in kN, while the deformation, i.e., the spring travel I, for example in millimeters, is plotted along the ordinate. The spring characteristic K clearly has a first section K1 with a steeper slope and a subsequent second section K2 with a slightly shallower slope. This corresponds to the respective spring constants of the different materials 3 and 5. While the characteristic curve in section K1 is defined only by the second material 5, in the second section K2 it is defined by both materials 3 and 5, since both are subjected to load.

[0033] Figure 3 shows a further embodiment of a tuning disc 1 according to the invention, which again consists of a first section 2 made of a first material 3, and a second section 4 made of a second material 5, which here, however, are arranged axially one behind the other, i.e., the two different materials 3, 5 are additively deposited axially on top of each other. In the event of force being applied, the force is therefore applied simultaneously to both materials.

[0034] The first section 2 has a first cavity 6, the second section 4 has a second cavity 7, which have slightly different geometries. These cavities influence the stiffness behavior of the respective section and can also be used, for example, as cooling channels or as temperature equalization elements.

[0035] In the event of force application, as described, a simultaneous load is applied to sections 2, 4, so that the characteristic curve ultimately results from the spring constants of the two different materials 3, 5 as well as from the corresponding geometries of the cavities 6, 7.

[0036] Figure 4 shows an example of such a spring characteristic curve K, which is represented here as a progressive characteristic curve, i.e., it is non-linear over its entire length, the deformation or spring travel decreases successively with increasing force.

[0037] Figure 5 shows an embodiment of a tuning disc 1, which is designed as a disc spring assembly 8. It is made of only one material. It can be seen that it has several spring sections 9 arranged at angles to one another, as well as two disc-shaped axial edge sections 10 with which it abuts the adjacent bearing surfaces. The angles that the spring sections 9 have to each other and to the edge sections 10 vary along the axial length of the disc spring assembly 8.

[0038] The characteristic curve of such a spring design shows, for example, a characteristic curve K, as shown in Figure 6. The shape of the characteristic curve K versus the force F is determined, on the one hand, by the material from which the additively manufactured disc spring assembly 8 is made, and on the other hand, by the corresponding geometry of the disc spring assembly, resulting in a progressive curve. This is because the individual disc spring sections exhibit different spring behaviors due to their different angular positions; these behaviors, however, superimpose, resulting in the characteristic curve shown in Figure 6.

[0039] While Figure 5 shows a tuning disc 1 made of one material, Figure 8 shows a tuning disc 1, also in the form of a disc spring assembly 8, but consisting of two different materials 3 and 5. A first section 2 is formed over material 3, and a second section 4 over material 5. Here, the characteristic curve K, as exemplified in Figure 8, is additionally determined by the properties of the different materials 3 and 5 as well as the corresponding geometry of the disc spring assembly, resulting in a progressive characteristic curve K, which, however, has a slightly different slope, especially at higher forces, compared to the example in Figure 6.

[0040] Figure 9 shows an embodiment of a tuning disc 1, again in the form of a disc spring assembly 8, which is made of only one material. Here, the spring sections 9 are at almost equal angles to each other; in the example shown, no edge sections 10 are provided. However, the disc spring assembly 8 widens, as Figure 9 clearly shows. A corresponding spring characteristic curve K is shown as an example in Figure 10.

[0041] An example of the tuning disc 1 in the form of a disc spring assembly 8 made of two different materials is shown in Figure 11. A first section 2 made of a first material 3 and a second section 4 made of a second material 5 are provided, wherein the materials 3 and 5 have different hardnesses, and therefore also different spring constants. For example, the spring constant of the first material 3 is significantly greater than the spring constant of the second material 5. Here, too, the disc spring assembly 8 expands, similarly to the description in Figure 9.

[0042] Figure 12 shows an example of a corresponding spring characteristic curve K. This curve is relatively steep at the beginning of the force application because initially the softer material compresses first, for example until the first coil reaches its limit, after which the second material also compresses accordingly and the characteristic curve K flattens out. With such a design, for example, a relatively large temperature-induced play can be compensated for, while the preload is only minimally affected.

[0043] Figure 18 shows a tuning disc 1, again manufactured from a single material, with the tuning disc 1 having a plurality of individual cavities 11 in the cross-section shown. The tuning disc 1 varies in width radially, thus having narrower and wider sections, with corresponding cavities 11 formed in both the narrower and wider sections. This is easily achieved during manufacturing due to additive manufacturing. The narrower sections have smaller cavities 11, while the wider sections have larger cavities 11. The cavities 11 naturally run in a ring around the circumference of the disc. For example, when a load is applied to the components 12 and 13 shown here as examples, spaced apart by the tuning disc 1, a somewhat flatter characteristic curve K is obtained, as shown in Figure 14.

[0044] In contrast, Figure 15 shows a tuning disk 1, which in turn consists of two separate sections 2 and 4. Section 2 is made of a first material 3, and section 4 of a second, for example, harder material. This means that sections 2 and 4 again have different spring constants. The cross-sectional geometry is identical to that of Figure 7, thus also featuring narrower and wider sections with corresponding narrower and wider cavities 11. Under load, a relatively steep characteristic curve K results, as shown in Figure 16. Initially, the section consisting of the somewhat softer material compresses first, potentially reaching almost to its limit. Only then does the second, harder section compress, resulting in a flattening of the progressive curve. Such a tuning disk makes it possible to accommodate even larger external displacements, e.g.,Temperature-related variations can be compensated for in a virtually preload-neutral manner. For example, such a tuning disc 1 could be used to implement a virtually instantaneous limitation of the travel, for instance to hold gears on a shaft within specific ranges.

[0045] As described, the invention is not limited to the initial example shown, but allows any variations with regard to both the choice of material and the geometry.

[0046] List of reference signs

[0047] 1 tuning disc

[0048] Section

[0049] material

[0050] Section

[0051] material

[0052] cavity

[0053] cavity

[0054] 8 Belleville spring pack

[0055] 9 Spring section

[0056] 10 Marginal section

[0057] 11 Cavity

[0058] 12 components

[0059] 13 Component

[0060] K spring characteristic curve

Claims

Patent claims 1. Tuning disc consisting of at least one additively deposited material (3, 5), wherein the tuning disc (1 ) has a non-linear spring characteristic (K).

2. Tuning disc according to claim 1, characterized in that the spring characteristic curve (K) has at least two linear sections (K1, K2) having different slopes, or that the spring characteristic curve (K) has at least one section having a progressive slope, at least one section having a degressive slope, or at least one section having a progressive slope and at least one section having a degressive slope.

3. Tuning disc according to claim 1 or 2, characterized in that it consists of only one material and has a geometry that defines an axial spring travel with a non-linear spring characteristic (K) when a force is applied.

4. Tuning disc according to claim 1 or 2, characterized in that it consists of at least two different materials (3, 5) and has a geometry that defines an axial spring travel with a non-linear spring characteristic (K) when a force is applied.

5. Tuning disc according to claim 3 or 4, characterized in that it is designed in the manner of a disc spring assembly (8).

6. Tuning disc according to claim 3 or 4, characterized in that it has one or more cavities (11 ).

7. Tuning disc according to claims 4 and 6, characterized in that the cavity(s) (11) are provided in only one material (3, 5) or in both materials (3, 5).

8. Tuning disc according to claim 6 or 7, characterized in that the cavities (11) extend in the circumferential direction of the disc.

9. Tuning disc according to claim 4, or claim 4 and one of claims 5 to 8, characterized in that the two materials (3, 5) are arranged axially one behind the other with respect to a force direction, or that the two materials (3, 5) are arranged radially next to each other with respect to a force direction and one material (3, 5) projects axially beyond the other.

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