Clutch Pack Pre-Build Fixture With Gravity Release 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 inefficiencies in aligning and stacking clutch plates and springs, necessitating manual operation and separate feed systems.
Innovation Solution
A clutch pack assembly tool featuring a base, guide members, and a release mechanism that uses gravity-assisted fingers to coaxially align and stack clutch components, allowing for efficient loading and release into a clutch housing, reducing manual labor and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional stacking equipment is used to assemble clutch packs, then alignment and stacking can be automated, but the equipment is expensive and requires considerable maintenance
Solution Approach 1:
The tool is divided into separate modular components: a handle assembly, multiple guide members (first, second, and third guide members), and a release mechanism. Each component can be independently manufactured, maintained, or replaced, reducing overall system complexity and maintenance costs while maintaining automated alignment and stacking capabilities.
Solution Approach 2:
The release mechanism uses gravity and spring forces to automatically release the clutch pack from the guide members without requiring additional actuators or complex control systems. The tool feeds itself through the natural gravitational force on the clutch pack, eliminating the need for powered ejection mechanisms.
2Productivity
If traditional stacking equipment is used, then clutch packs can be stacked, but the equipment does not produce enough stacks to support high volume production lines
Solution Approach 1:
The guide members are pre-configured with specific geometries and orientations that automatically align clutch plates and springs as they are placed into the tool. The third guide member pre-positions the clutch pack in the correct orientation before release, enabling rapid assembly without complex alignment procedures and supporting high-volume production.
Solution Approach 2:
The release mechanism dynamically transitions from a locked position (holding the clutch pack during assembly) to an unlocked position (releasing the clutch pack for installation). This dynamic operation allows the tool to rapidly cycle through assembly operations, increasing productivity for high-volume production lines.
3Ease of operation
If traditional stacking equipment is used, then clutch packs can be assembled, but one operator must manually unload stacks and place them on a separate feed system
Solution Approach 1:
The tool combines the alignment, stacking, and release functions into a single integrated device. The clutch pack is assembled and released in one continuous operation, eliminating the need for separate unloading and transfer operations. The guide members and release mechanism work together to directly position the clutch pack for installation, reducing manual intervention and cycle time.
4Manufacturing precision
If manual alignment of clutch plates is performed, then rotational orientation can be achieved, but the process is time consuming
Solution Approach 1:
The guide members act as intermediaries between the operator and the clutch components. The first and second guide members guide the clutch plates into correct rotational orientation, while the third guide member mediates the final positioning of the clutch pack. These intermediary guide structures eliminate the need for manual alignment adjustments, achieving precise rotational orientation rapidly.
Solution Approach 2:
The patent replaces manual mechanical alignment operations with a guided mechanical system. Instead of operators manually rotating and positioning clutch plates, the guide members' geometries and constraints automatically achieve the required rotational orientation through controlled mechanical interaction, significantly reducing alignment time.
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, more efficient assembly of clutch packs with reduced manual intervention, supporting high-volume production by automating the alignment and stacking process while minimizing maintenance needs.
Implementation Method 1
the counter weight is gravity biased 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 tool for assembling components of a clutch pack coaxially about an axis includes a base, a first guide member, and a second guide member. The first guide member is coupled to the base and has a first guide face configured to matingly engage a toothed portion of an inner clutch plate of the clutch pack. A top portion of the first guide face is radially inward of a bottom portion of the first guide face. A second guide member is coupled to the base and spaced apart from the first guide member. The second guide member has a second guide face configured to matingly engage the toothed portion of the inner clutch plate of the clutch pack. A top portion of the second guide face is radially inward of a bottom portion of the second guide face.