Clutch Pack Pre-Build Fixture for Fast Coaxial Plate Alignment
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Solution Overview
Problem
Traditional equipment for assembling clutch packs is expensive, requires significant maintenance, and cannot support high-volume production due to the time-consuming manual alignment and stacking process, with a need for multiple operators to unload and install components into the clutch housing.
Innovation Solution
A clutch pack assembly tool featuring a base, guide members, and a release mechanism that includes a counterweight to support and align clutch pack components coaxially, allowing for efficient stacking and automatic release into the clutch housing, reducing manual labor and increasing production capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stacking equipment is used, then clutch packs can be assembled, but the equipment is expensive, requires considerable maintenance, and cannot support high volume production
Solution Approach 1:
The tool is divided into separate modular components including a base, multiple guide members, and a release mechanism. Each component performs a specific function and can be independently manufactured and assembled, reducing overall device complexity while maintaining productivity capabilities
Solution Approach 2:
The release mechanism uses a counterweight that automatically triggers the release of clutch packs through gravitational force. The system serves itself by using the weight of the tool and counterweight to perform the release action without requiring additional actuators or complex control systems
2Manufacturing precision
If manual alignment of clutch plates is performed, then alignment can be achieved, but the process is time consuming and reduces productivity
Solution Approach 1:
The guide members are pre-configured with guide faces that automatically align clutch plates as they are placed into the tool. This preliminary alignment action eliminates the need for manual adjustment during assembly, maintaining precision while increasing speed
Solution Approach 2:
The guide members act as intermediary elements between the operator and the clutch plates. They provide the alignment function that would otherwise require manual skill, transferring the alignment capability from the operator to the tool itself
3Ease of operation
If traditional stacking equipment is used, then clutch packs can be stacked, but one operator must manually unload stacks and place them on a separate feed system
Solution Approach 1:
The stacking and feeding functions are merged into a single integrated tool. The clutch packs are stacked and fed directly into the clutch housing through the same device, eliminating the need for separate feed systems and manual transfer operations
Solution Approach 2:
The tool enables continuous operation by maintaining clutch packs in a ready-to-install state within the same device. The integrated design allows for uninterrupted flow from stacking to installation, eliminating idle time and manual handling interruptions
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 tool enables faster and more efficient assembly of clutch packs, reducing production costs and improving alignment accuracy, thus supporting high-volume production with fewer operators, while maintaining alignment precision and reducing manual handling errors.
Implementation Method 1
the counter weight is supported for axial translation between the first position and the second position, wherein gravity biases the counterweight toward the first position in which the counter weight holds the at least one finger in the extended position
Implementation Method 2
in the retracted position the components of the clutch pack are permitted to fall from a bottom of the tool
Data Source
AI summary
A method and tool system coaxially orients inner clutch plates with outer clutch plates on a tool. The tool includes a plurality of guide members circumferentially spaced apart, each guide member matingly engages a toothed portion of each inner clutch plate to position the inner clutch plates coaxially. A pre-build fixture includes a plurality of alignment pillars, at least one support block, and an alignment member. The alignment pillars are circumferentially spaced apart about a fixture axis. Each alignment pillar has a curved inner face that faces radially inward and has an arclength that is configured to coincide with and fit within a corresponding gap between radially outward facing teeth of each outer clutch plate. The support block supports the tool coaxially with the fixture. The alignment member engages the tool to inhibit rotation of the tool when the tool is supported coaxially with the fixture by the support block.