Bushing-Type Roller Overrunning Clutch Cage Integration
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Solution Overview
Problem
Existing bushing-type roller overrunning clutches are cost-intensive due to their assembly from numerous separate parts, which complicates manufacturing and increases costs without improving functionality.
Innovation Solution
The inner or outer ring is integrated with cage elements, eliminating the need for a separate cage by deep-drawing the ring with clamping ramps and forming spring-retaining lugs and tabs to guide needles or rollers, allowing for a one-piece construction that simplifies assembly and reduces costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the overrunning clutch is assembled from numerous separate parts (outer ring, inner ring, cage, needles, pressure springs), then the clutch meets all functional requirements and proves its worth, but the manufacturing cost increases and the assembly process becomes complex
Solution Approach 1:
The patent combines the outer ring and cage into a single integrated component called a 'bushing'. The cage elements are formed as integral parts of the bushing through deep-drawing processes, eliminating the need for separate assembly of the cage and outer ring. This merging reduces the total number of parts while maintaining all necessary functions including needle guidance, clamping ramp support, and structural integrity.
Solution Approach 2:
The integrated bushing performs multiple functions simultaneously: it serves as the outer ring providing structural support, forms clamping ramps for needle engagement, creates cage elements for needle guidance, and incorporates borders and spring-retaining lugs for spring mounting. This multi-functionality eliminates the need for separate specialized components while maintaining reliable operation.
2Manufacturing precision
If a separate cage component is used with high dimensional exactitude, then precise needle guidance is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The cage elements are merged with the bushing as integral formations rather than separate components. The deep-drawing process creates precise cage geometry directly in the bushing structure, eliminating the need for separate high-precision cage manufacturing and assembly. The cage elements emerge as built-in features of the single-piece bushing.
3Ease of manufacture
If numerous separate parts are assembled, then the clutch can be manufactured using standard components, but assembly time and production costs increase
Solution Approach 1:
The bushing is pre-formed as a complete integrated unit with all cage elements, borders, and spring-retaining lugs already in their final positions and configurations. This preliminary formation of the complete structure eliminates the need for subsequent assembly operations, allowing the clutch to be rapidly assembled by simply installing needles and springs into the pre-configured bushing.
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 integration reduces production costs and maintains the clutch's operational efficiency by eliminating the need for precise, separate cage components, while ensuring reliable guidance and retention of rollers, thus enhancing the overall manufacturing efficiency and cost-effectiveness.
Implementation Method 1
the inner or the outer ring is deep-drawn together with the clamping ramps and with at least one border arranged on one side of the clamping ramps
Implementation Method 2
spring-retaining lugs are cut out of the border and that the spring-retaining lugs are bent radially towards the inner or outer ring
Data Source
AI summary
A bushing-type roller overrunning clutch comprising at least an inner or an outer ring that comprises clamping ramps adapted to the needles or rollers, said overrunning clutch further comprising a cage for the needles or rollers, as also pressure springs, said cage comprising cage elements that are made in one piece with the inner or outer ring, and a method of making a bushing-type roller overrunning clutch in which the inner or outer ring together with the clamping ramps and at least one border arranged on one side of the clamping ramps is made by deep-drawing, spring-retaining lugs are cut out of the border, and the spring-retaining lugs are bent radially towards the inner or outer ring and the free-standing tabs of the spring-retaining lugs are bent over into the region of the clamping ramps.