Surface-Coated Clutch Damper Assembly for Clonk Noise Reduction
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Solution Overview
Problem
Existing clutch systems experience noise, vibration, and harshness issues due to backlash and increased impact loading, which are exacerbated by the need to reduce friction between drivetrain components to meet efficiency and emissions standards.
Innovation Solution
A torque transfer plate with a surface coating that provides acoustic damping, reducing the noise and vibration associated with impact loading, while maintaining the functional integrity of the clutch system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If friction between drivetrain components is reduced to meet efficiency and emissions standards, then energy efficiency is improved, but noise and vibration increase
Solution Approach 1:
A damper assembly is introduced as an intermediary component between the torque transfer plate and output shaft. This damper assembly absorbs impact loads and reduces vibration, allowing the clutch system to operate with reduced friction while maintaining acceptable noise and vibration levels.
Solution Approach 2:
The damper assembly utilizes composite material structures, including damping materials and elastomeric elements, to simultaneously reduce vibration and absorb impact energy. This composite approach enables the system to achieve both low friction operation and acceptable acoustic performance.
2Object-generated harmful factors
If backlash between clutch components is increased to reduce rattle, then noise is reduced, but impact loading increases
Solution Approach 1:
The damper assembly converts the harmful impact loading resulting from increased backlash into beneficial damping action. The damping elements absorb and dissipate the impact energy, transforming what would be destructive shock loads into controlled energy dissipation, thereby reducing rattle noise while managing impact forces.
Solution Approach 2:
The damper assembly provides beforehand cushioning by positioning damping elements in advance between the torque transfer plate and output shaft. These elements are pre-positioned to absorb and cushion upcoming impact loads, preventing direct transmission of shock forces while maintaining the increased backlash necessary for rattle reduction.
3Object-generated harmful factors
If assembly tolerances are tightened to reduce backlash, then clonk is reduced, but manufacturing complexity increases
Solution Approach 1:
The damper assembly provides self-service by automatically compensating for assembly tolerances and backlash variations. The damping elements self-adjust to accommodate manufacturing variations, eliminating the need for tight tolerance control during assembly while still reducing clonk noise through vibration damping.
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
The surface-coated torque transfer plate effectively reduces undesirable audible sounds such as clonk, improving the overall noise, vibration, and harshness characteristics of the clutch system.
Implementation Method 1
A torque transfer plate for a clutch, the torque transfer plate having acoustic properties which result in the torque transfer plate being at least partially silenced when impacted by another object
Data Source
Figure 1~2
AI summary
A damper assembly for a clutch, the damper assembly being configured to transfer torque from a driven plate of the clutch to an output shaft of the clutch, the damper assembling comprising a torque transfer plate comprising at least one functional surface coating configured to alter the acoustic properties of the torque transfer plate.