Ball-Ramp Clutch Actuator with Molded Support Ring Force Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing clutch assemblies face challenges in efficiently transmitting axial force to squeeze friction plates and separator plates, particularly in high-volume manufacturing, where cost-effective and durable solutions for actuator assemblies are lacking.
Innovation Solution
The actuator assembly employs stamped ramp plates, rolling elements, and support rings, where the first support ring is molded plastic, radially locating a thrust bearing to transmit axial force, and the second support ring has gear teeth, allowing for economical and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional actuator assemblies are used to transmit axial force to the clutch pack, then the clutch assembly can operate, but the manufacturing cost increases and high-volume production efficiency decreases
Solution Approach 1:
The actuator assembly is segmented into distinct functional components: ramp plates, rolling elements, support rings, and thrust bearings. This segmentation allows each component to be manufactured separately using optimized processes (stamping for ramp plates, molding for support rings) and then assembled, reducing overall manufacturing cost while maintaining production efficiency.
Solution Approach 2:
The patent replaces traditional mechanical fastening and locating systems with a ball-ramp mechanism that uses rolling elements between inclined surfaces. This substitution eliminates complex machining operations and enables the use of stamped and molded parts, significantly reducing manufacturing cost for high-volume production.
2Ease of manufacture
If cost-effective materials and manufacturing methods are used for the actuator assembly, then manufacturing cost decreases, but the ability to transmit axial force efficiently and maintain durability may worsen
Solution Approach 1:
The actuator assembly uses a composite approach combining stamped metal ramp plates for structural strength, molded plastic support rings for cost-effective positioning, rolling elements for smooth operation, and thrust bearings for reliable axial force transmission. This composite material strategy maintains durability and force transmission efficiency while reducing manufacturing cost.
Solution Approach 2:
The patent introduces intermediary components (support rings and thrust bearings) that mediate between the cost-effective stamped/molded parts and the axial force transmission requirement. The support rings provide precise radial location, and the thrust bearings ensure efficient axial force transmission, bridging the gap between low-cost manufacturing and high reliability.
3Device complexity
If the actuator assembly uses simple stamped and molded components, then device complexity decreases and manufacturing cost reduces, but the precision of radial location and axial force transmission may worsen
Solution Approach 1:
The support rings are designed to self-locate the thrust bearings radially through their geometric features, eliminating the need for complex external locating mechanisms. The stamped ramp plates and molded support rings incorporate built-in alignment features that automatically ensure precise radial location during assembly, maintaining manufacturing precision while reducing device complexity.
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
This configuration enables efficient transmission of axial force to the clutch pack, allowing for cost-effective and high-volume production while maintaining durability, effectively controlling the engagement and disengagement of clutch components.
Implementation Method 1
a plurality of rolling elements interposed between the first and second ramp plates such that relative rotation between the ramp plates in an apply direction forces the ramp plates apart
Implementation Method 2
The first support ring has a feature to radially locate a thrust bearing and is configured to transmit axial force from the first ramp plate to the thrust bearing
Data Source
AI summary
A ball-ramp clutch includes two stamped ramp plates and at least one molded support ring. The molded support ring transmits axial force from one of the ramp plates to a thrust bearing, which, in turn, transmits the axial force to the pressure plate of a clutch pack. The molded support ring may radially locate one of the races of the thrust bearing. The molded support ring may be plastic.