Clutch Module Assembly Using Angular Pairing to Reduce Drag

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Solution Overview

Problem

Manufacturing tolerances in clutch modules lead to radial axial dimension deviations between pressing elements, causing undue contact and excess pressure, resulting in harmful heating and premature wear.

Innovation Solution

A method of assembling a clutch module that positions pressing elements relative to each other based on their dimensional characteristics to minimize drag forces and excess pressure, using marks to identify and angularly pair components to compensate for manufacturing tolerances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pressing elements are assembled using conventional manufacturing tolerances, then assembly is simpler and faster, but radial axial dimension deviations cause undue contact, drag forces, and premature wear

Engineering Contradiction:

Improveclutch module service lifeVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by determining and marking the position of maximum axial movement on pressing elements before assembly. This pre-positioning information allows the components to be correctly aligned during assembly, compensating for manufacturing tolerances and preventing undue contact between pressing elements and friction discs, thereby extending clutch module service life without requiring complex adjustment procedures during assembly

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the conventional mechanical assembly approach (relying solely on manufacturing tolerances and force-fit alignment) with a marking and positioning system. By using visual markers to indicate maximum axial movement positions, the system substitutes precise mechanical forcing with a guided alignment process, reducing drag forces and excessive pressure while maintaining assembly simplicity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If pressing elements are assembled without position alignment, then assembly is faster and easier, but axial dimension deviations induce drag forces and excess pressure

Engineering Contradiction:

Improveassembly speedVSAvoiddrag forces and excess pressure

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The marking of maximum axial movement positions is performed in advance on each pressing element. During assembly, these pre-marked positions are quickly aligned, enabling fast assembly without requiring complex real-time measurements or adjustments. This preliminary preparation eliminates drag forces and excess pressure by ensuring correct positioning from the start, maintaining high productivity while preventing harmful effects

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses visual markers as copies or indicators of the critical positioning information (maximum axial movement position). These markers serve as simplified representations of the complex dimensional relationships, allowing assembly workers to quickly align components based on the marked positions without needing to understand or measure the underlying axial dimension deviations, thus maintaining assembly speed while eliminating harmful drag forces

Inventive Principle:

Principle #26Copying

3Reliability

If pressing elements are positioned to compensate for dimensional deviations, then drag forces and wear are reduced, but assembly process becomes more complex

Engineering Contradiction:

Improveclutch module durabilityVSAvoidassembly procedure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The complex positioning information is prepared in advance by marking the maximum axial movement positions on each pressing element during manufacturing or pre-assembly. This transfers the complexity from the assembly stage to the manufacturing stage, where marking can be easily performed. During final assembly, workers simply need to align the marked positions, significantly reducing procedural complexity while ensuring optimal positioning for reduced wear and enhanced durability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The marking system acts as an intermediary that translates complex dimensional compensation requirements into simple visual alignment cues. Instead of requiring assembly workers to perform complex measurements and calculations to compensate for manufacturing tolerances, the markers serve as intermediaries that guide the positioning process, reducing assembly procedure complexity while achieving the same durability benefits

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3748183B1Method for assembling a clutch module of a vehicle and clutch module assembled by implementing such a method

Publication Date: 2025.09.03 VALEO EMBRAYAGES SAS

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AI summary

The present invention relates to a method for assembling a vehicle clutch module (10) comprising a pack of discs (101a, 101b, 102a, 102b), a first pressing element (103a, 103b) of the pack of discs and a second pressing element (105a, 105b) of the pack of discs, a method in which: - a position of a maximum axial travel point of at least one of the components of the transmission device is determined, - a position of a maximum axial travel point of at least one of the other components of the transmission device is determined, - the axial travel points determined previously are identified, - the components of the transmission device are assembled by positioning the maximum axial travel point so as to angularly match the transmission device.