Buckled Split Tolerance Ring for Stable Torque Transmission
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Solution Overview
Problem
Existing tolerance rings face challenges in accommodating tight torque ranges between inner and outer members, requiring improved designs for precise torque transmission and overload protection in assemblies.
Innovation Solution
The tolerance ring design features a split ring with buckled regions and wave structure regions, which form an interference fit with the inner and outer members, allowing for precise torque transmission and overload protection by adjusting stiffness and contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a tolerance ring uses a simple band design with stamped projections, then it can accommodate variations in diameter between inner and outer members, but it cannot provide precise torque transmission within tight torque ranges
Solution Approach 1:
The tolerance ring is divided into multiple functional zones: wave structure regions with alternating peak and valley circumferential locations, and intermediate regions between them. This segmentation allows different portions of the ring to perform different functions - the wave structures provide elastic deformation for torque control while the intermediate regions provide stable contact surfaces, enabling precise torque transmission within tight torque ranges.
Solution Approach 2:
Different regions of the tolerance ring are given different geometric properties. The wave structure regions have varying wall thicknesses and curvature radii to create specific stiffness characteristics, while the intermediate regions have different contact surface geometries. This local differentiation of properties allows the ring to simultaneously achieve precise torque control and stable force transmission across the radial gap.
2Reliability
If a tolerance ring is designed to provide overload protection within very precise predetermined torque values, then it can protect assemblies from damage, but it becomes difficult to manufacture with consistent performance
Solution Approach 1:
The wave structures are pre-formed during manufacturing with specific geometric parameters (wall thickness, curvature radius, amplitude) that predetermined their elastic deformation characteristics. This preliminary formation of the buckled configurations ensures that the tolerance ring will consistently achieve the desired torque values without requiring complex post-manufacturing adjustments, improving both reliability and manufacturability.
Solution Approach 2:
The invention controls specific geometric parameters of the wave structures (amplitude, wavelength, wall thickness distribution) to tune the elastic deformation behavior. By precisely controlling these parameters during manufacturing, the tolerance ring achieves consistent predetermined torque values for overload protection while maintaining ease of manufacture through standardized geometric features.
3Stability of the object's composition
If a tolerance ring uses projections to span the radial gap and transmit forces, then it can accommodate diameter variations, but it cannot maintain stable torque transmission under varying loads
Solution Approach 1:
The wave structures are designed to dynamically adapt their deformation state based on the applied load. Under normal operating loads, the wave structures remain relatively undeformed, providing stable torque transmission. When loads exceed predetermined thresholds, the wave structures buckle and deform elastically, absorbing excess energy and maintaining stable force transmission across the radial gap throughout the deformation process.
Solution Approach 2:
The tolerance ring utilizes the elastic flexibility of thin-walled cylindrical structures. The wave-given wall portions act as flexible elements that can deform under load while maintaining structural integrity. This flexibility allows the ring to accommodate varying loads and diameter variations while the overall circular geometry maintains stable torque transmission characteristics across different operating conditions.
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 design effectively spans radial gaps with consistent torque transmission and overload protection, maintaining stability and preventing relative movement between components, even under varying loads.
Implementation Method 1
The tolerance ring design features a split ring with buckled regions and wave structure regions, which form an interference fit with the inner and outer members, allowing for precise torque transmission and overload protection by adjusting stiffness and contact points.
Data Source
AI summary
An assembly including an outer member; an inner member; and a tolerance ring disposed between the inner member and the outer member, wherein the tolerance ring is a split ring comprising opposing edges, where the edges engaged with at one of the inner member or the outer member so as to prevent or restrict movement between the tolerance ring and at least one of the inner member or the outer member, or where the tolerance ring is deformed as installed between the inner member and the outer member and forms at least one buckled region in the tolerance ring due to an interference fit between the inner member and the outer member, where in an uninstalled state, the buckled region is absent.