Chambered Pulley Assembly With Interlocking Torque Transfer Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary devices in vehicular engines, such as pulleys, are labor-intensive and expensive to manufacture due to the use of long welded joints, which complicates the torque transfer process between shafts and external torque members.
Innovation Solution
A rotary device comprising a shaft adapter, a chambered member with a circumferential portion and a separate side wall, and a seal member, where the side walls have torque transfer surfaces with projections and valleys that allow for efficient torque transfer without plastic deformation, and an axial locking mechanism to secure the components, reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welded joints are used to connect chambered member components, then structural strength is improved, but manufacturing complexity and labor cost increase
Solution Approach 1:
The chambered member is divided into separate components (circumferential portion, first side wall, second side wall) that can be manufactured independently and then assembled through interference fits, eliminating the need for complex welding operations while maintaining structural integrity
Solution Approach 2:
The welding process is extracted/removed from the manufacturing process entirely. Instead of joining components through welding, the patent uses interference fit connections between the circumferential portion and side walls, simplifying manufacturing while preserving strength
2Power
If projections and valleys are designed with no clearance, then torque transfer efficiency is improved, but risk of plastic deformation increases
Solution Approach 1:
The projections and valleys are designed with specific local geometric properties (dimensions, shapes, distributions) that optimize torque transfer in the circumferential direction while maintaining adequate clearance in the axial direction to prevent plastic deformation
Solution Approach 2:
The patent optimizes parameters such as projection height, valley depth, and clearance dimensions to achieve the balance between torque transfer efficiency and prevention of plastic deformation. The no clearance condition applies specifically to the circumferential direction where torque transfer occurs
3Stability of the object's composition
If axial locking projection is added to lock side wall, then axial stability is improved, but device complexity increases
Solution Approach 1:
The axial locking projection is integrated into the existing side wall component rather than being a separate part. The locking mechanism utilizes the interference fit structure already present between the circumferential portion and side walls, adding axial locking functionality without significantly increasing overall device complexity
Data Source
AI summary
In one aspect, a rotary device is provided, and includes a shaft adapter, a chambered member, a seal member and at least one internal torque transfer member. The shaft adapter is connectible to a crankshaft or accessory shaft and defines an axis. The chambered member (e.g. a pulley) is rotatably connected to it, and at least partially encloses a chamber (e.g. for oil), and includes a circumferential portion, a first side wall, and a second side wall which is a separate member from the circumferential portion. One of the circumferential portion and the second side wall has projections thereon, and the other has valleys that mate with the projections with no clearance, so as to be able to transfer a torque of at least 10 Nm into one another without plastic deformation. A seal member is compressed between the second side wall and the circumferential portion.