Aligned Variable-Turn Wave Springs for Stable Component Preload
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Solution Overview
Problem
Wave springs with multiple variable turns face challenges in generating consistent loads due to misalignment of active and non-active turns, leading to inefficient pre-loading of components and potential torsional loads that can cause vibration and wear in applications like automotive e-motors.
Innovation Solution
A wave spring design with aligned active and non-active turns, where at least two waved or non-planar turns are aligned with each other, and non-active turns are strategically placed between these turns to manage load distribution, allowing for adjustable load generation and reduced torsional stress through specific coiling methods and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wave springs have multiple variable turns with misaligned active and non-active turns, then the spring can accommodate variable loads, but the load distribution becomes inconsistent causing vibrations and wear
Solution Approach 1:
The wave spring is segmented into distinct active turns and non-active turns, with each segment serving a specific function. The active turns are positioned to align with each other to handle variable loads, while non-active turns are strategically placed to maintain structural stability and ensure consistent load distribution, preventing vibrations and wear.
Solution Approach 2:
Different regions of the wave spring are given different properties: active turns are designed with specific geometry to accommodate variable loads, while non-active turns are configured to provide structural support and maintain alignment. This local differentiation ensures that each part of the spring contributes optimally to both adaptability and reliability.
2Productivity
If wave springs generate higher loads through aligned turns, then pre-loading efficiency improves, but the device complexity increases due to specific coiling methods required
Solution Approach 1:
The wave spring is pre-formed during manufacturing with active turns already aligned in the correct positions and non-active turns strategically placed. This preliminary configuration ensures that when the spring is installed, it immediately provides efficient pre-loading without requiring additional adjustment or complex assembly procedures, thereby improving productivity while managing device complexity.
3Object-affected harmful factors
If non-active turns are placed between aligned active turns, then torsional stress is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
Non-active turns serve as intermediary elements positioned between the aligned active turns. These intermediary turns act as spacers and stress distributors, reducing torsional stress by providing structural support and preventing direct contact between adjacent active turns. The manufacturing process incorporates fixtures and guides to ensure precise positioning of these intermediary turns, meeting the required precision standards.
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 aligned wave spring design effectively manages load distribution, reducing vibrations and wear by generating higher or lower loads as needed, improving the pre-loading efficiency and longevity of components in applications like automotive e-motors.
Implementation Method 1
The wave spring may comprise a total height defined by a first end portion and a second opposite end portion, an intermediate portion disposed between the first and second end portions
Implementation Method 2
a method may comprise coiling a flat wire onto itself to produce the present wave spring
Data Source
AI summary
Wave springs having multiple variable turns, methods of pre-loading components with said wave springs, and methods of manufacturing said wave springs are provided. The wave spring has a total height defined by a first end portion and a second opposite end portion and an intermediate portion disposed between the first and second end portions. The intermediate portion has active turns with waved or non-planar turns and non-active turns with planar or non-waved turns. The wave spring also has a first alignment disposed between the first and second end portions, wherein first alignment comprises at least two waved or non-planar turns being aligned with each other.