Multi-Disk Clutch End Disk With Variable Impressions for Tolerance Control
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Solution Overview
Problem
Multi-disk clutches face high manufacturing and storage costs due to the need for various end disk thicknesses to maintain tolerance, requiring multiple thickness options and additional finishing processes.
Innovation Solution
The end disk features a ring plate with variable axial impressions and projections, allowing for adjustable thickness using the same sheet metal wall thickness, enabling individual adaptation to different applications without additional finishing, and forming a modular system for selecting appropriate end disks based on disk pack thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple end disk thicknesses are used to maintain tolerance, then manufacturing precision is improved, but device complexity and storage costs increase
Solution Approach 1:
A single end disk design with variable impression depths serves multiple thickness requirements. The ring plate can be produced with different impression depths to create projections of varying heights, allowing one base design to fulfill multiple thickness specifications (5-10 different thicknesses) while maintaining manufacturing precision for disk pack length tolerance.
Solution Approach 2:
The thickness of the end disk is varied by changing the depth parameter of the axial impression rather than creating entirely different disk designs. By controlling the impression depth, projections of different heights are formed, enabling precise adjustment of end disk thickness to compensate for intermediate disk tolerance variations while reducing the number of distinct part variants.
2Manufacturing precision
If end disks are ground down from uniform thickness, then manufacturing precision is improved, but manufacturing costs and time increase
Solution Approach 1:
The required thickness variation is built into the end disk during the initial forming process by creating impressions of different depths, rather than starting with uniform thickness and removing material through grinding. This preliminary shaping eliminates the need for subsequent grinding operations, reducing manufacturing costs and process complexity while maintaining precise thickness control.
Solution Approach 2:
Material is selectively removed only where needed to create impressions of varying depths during the forming process, rather than uniformly grinding down the entire disk surface. This targeted material extraction achieves the required thickness precision while minimizing manufacturing effort and cost.
3Manufacturing precision
If disks of different thicknesses are manufactured separately, then manufacturing precision is improved, but storage and handling costs increase
Solution Approach 1:
A single ring plate design with variable impression depths replaces the need to manufacture and store multiple distinct end disk thickness variants. The same base design can be produced with different impression depths to meet various thickness requirements, significantly reducing storage space and handling complexity while maintaining accurate thickness control for assembly.
Data Source
AI summary
An end disk of a multi-disk clutch is described, which has a ring plate, the ring plate having a central opening and at least one axial impression on a front side via which a corresponding projection is formed on the opposite front side.