Adaptive Tensioner Lever for Chain Vibration and Load Fluctuations

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Solution Overview

Problem

Existing tensioner levers have a limited maximum load capacity due to fixed components, leading to inadequate reaction force during sudden chain behavior changes, such as engine startup or high-frequency resonance, resulting in vibration and noise issues.

Innovation Solution

A tensioner lever with a spring load adaption structure that forms a second loading point and/or support point when a certain load is reached, allowing load division and increased spring load, enabling consistent reaction force and reduced resonance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the pressing arm has a fixed length and the distal end portion is fixed to receive load, then the structure is simple, but the maximum load capacity of the torsion coil spring is limited

Engineering Contradiction:
Improvestructure simplicityVSAvoidmaximum load capacity
Core Design Contradiction:
Device complexityVSStrength

Solution Approach 1:

The pressing arm is designed with a variable length mechanism that allows it to extend or retract based on the load conditions. When the chain tension exceeds a certain threshold, the pressing arm automatically extends to a longer position, thereby increasing the lever arm and the maximum load capacity of the torsion coil spring. This dynamic adjustment resolves the contradiction by allowing the structure to remain simple (no complex control systems) while achieving higher strength when needed.

Inventive Principle:
Principle #15Dynamics

2Strength

If the torsion coil spring undergoes large elastic deformation to handle excessive load, then the load capacity increases, but the capability to follow sudden changes in chain behavior deteriorates

Engineering Contradiction:
Improveload capacityVSAvoidresponse to sudden chain behavior changes
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The variable length pressing arm dynamically adjusts the effective lever arm length based on load conditions. During sudden chain behavior changes (like engine startup or resonance), the pressing arm maintains an optimal length that allows the torsion coil spring to respond quickly without excessive deformation. This resolves the contradiction by preventing the spring from undergoing large elastic deformations while still handling excessive loads through the extended arm position.

Inventive Principle:
Principle #15Dynamics

3Device complexity

If the pressing arm has a fixed length, then the structure is simple, but it cannot exert correct reaction force when the chain bounces largely at engine startup or undergoes resonance

Engineering Contradiction:
Improvestructure simplicityVSAvoidresponse to varying chain behavior
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The pressing arm incorporates a variable length mechanism that automatically adjusts its effective length in response to different chain behavior conditions. During normal operation, it maintains a shorter length for simplicity. When the chain bounces largely at engine startup or undergoes resonance, the arm extends to provide the correct reaction force. This dynamic adaptation resolves the contradiction between structural simplicity and adaptability to varying chain behavior.

Inventive Principle:
Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution ensures consistent reaction force during chain fluctuations, reduces vibration and noise, and improves the lever's ability to follow chain behavior changes by optimizing the spring load and normal frequency.

Implementation Method 1

a torsion coil spring interposed between the lever body and the attachment surface to press the shoe surface toward the chain

Methodology Applied
Scientific EffectElasticity: Elasticity

Implementation Method 2

a torsion coil spring including a helical part loosely fitted to a cylindrical boss part provided to the lever body

Methodology Applied
Scientific EffectTorsion spring: Torsion Spring

Data Source

PatentUS11371591B2Tensioner lever
Publication Date: 2022.06.28 TSUBAKIMOTO CHAIN CO
  • US11371591B2 patent drawing
  • US11371591B2 patent drawing
  • US11371591B2 patent drawing

AI summary

An object of the present invention is to provide a tensioner lever capable of consistently exerting appropriate reaction force to various tension fluctuations in conjunction with varying chain behavior, and reducing vibration and noise when the chain runs. The tensioner lever of the present invention includes a torsion coil spring having a pressing arm in which a distal end portion abuts on a lever body to form a first load point, and a support arm in which a distal end portion abuts on a support part provided to an attachment surface to form a first support point. The tensioner lever further includes a spring load adaption structure configured to form one or both of a second loading point and a second support point when a certain level or more of load is received from the chain.