Clutch Disc Support Axial Flexibility Design
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Solution Overview
Problem
Existing clutch discs for friction clutches, particularly in motor vehicle transmissions, face issues with axial flexibility and production simplicity, leading to problems such as clutch chattering and squealing, especially in robotized gearboxes.
Innovation Solution
A clutch disc design featuring a support with increased axial flexibility, achieved by a radial offset between the spacer and friction lining, allowing the radially inner edge of the spacer to be at a greater distance from the hub axis than the friction lining, which increases the radial dimension of the support portion not in contact with the flange or spacer, without altering the friction surfaces or torque transmission performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support is made rigid to ensure structural strength, then strength is improved, but axial flexibility deteriorates leading to clutch chattering and squealing
Solution Approach 1:
The support is segmented into multiple radial portions (first, second, third portions) with different flexibility characteristics. The first radial portion has high axial flexibility to prevent clutch chattering and squealing, while the second and third portions maintain structural strength. This segmentation allows each portion to be optimized for its specific function.
Solution Approach 2:
Different regions of the support are given different local properties. The first radial portion (radially inner region) is designed with high axial flexibility through specific geometric features, while the second and third portions (radially outer regions) maintain higher rigidity. This local quality differentiation resolves the contradiction between overall flexibility and local strength requirements.
2Reliability
If the radial dimension of the support portion between flange and spacer is increased to improve axial flexibility, then axial flexibility is improved, but the friction surface area is reduced
Solution Approach 1:
The solution moves the flexibility enhancement from the radial dimension to the axial dimension. By creating axial offsets between the friction lining, intermediate piece, and flange, the first radial portion is given increased axial flexibility without reducing the radial extent of the friction surfaces. This dimensional shift allows flexibility improvement while preserving friction surface area.
Solution Approach 2:
The support is designed with dynamic flexibility in the axial direction through the first radial portion, allowing it to deform axially under load variations. This dynamic capability is achieved through geometric features in the first portion while maintaining the static friction surface geometry in the second and third portions.
3Ease of manufacture
If the clutch disc design is simplified to reduce production cost, then ease of manufacture is improved, but axial flexibility deteriorates
Solution Approach 1:
The support is divided into functional segments that can be manufactured using standard processes. The first, second, and third radial portions are defined by conventional geometric features (offsets, thickness variations) that can be produced with typical machining or forming operations, avoiding complex specialized manufacturing while achieving the desired flexibility gradient.
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 reduces clutch chattering and squealing by enhancing axial flexibility while maintaining torque transmission performance, and can be produced relatively simply and inexpensively.
Implementation Method 1
the support has a portion in which it is neither in direct contact with the flange nor in direct contact with the spacer. It is desirable that this portion of the support has a certain axial flexibility
Implementation Method 2
the friction surfaces capable of coming into contact with the pressure or reaction plate of the clutch
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A clutch disc (1) for a friction clutch, comprising: - a hub (3) extending along a longitudinal axis (X), - a flange (6) coupled to the hub (3), - a support (10) rigidly coupled to the flange (6) and extending radially beyond the flange (6), - a friction lining (12) rigidly connected to the support (10), and - a spacer (11) disposed axially between the support (10) and the friction lining (12), the portion of the radially inner edge (20) of the spacer (11) in contact with the support (10) being separated from the axis X of the hub (3) by a distance greater than the distance between said axis (X) and the radially inner edge (21) of the friction lining (12).