Clutch Outer Ring Engagement Structure Without Welding Distortion

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Solution Overview

Problem

The existing clutch unit designs, such as those described in Patent Literature 1, face issues with distortion and increased manufacturing complexity due to the welding process used to attach the output-side outer ring member to the housing, which complicates assembly and increases costs.

Innovation Solution

A clutch unit design that attaches the output-side outer ring member to the housing without welding, utilizing engagement structures between the output-side outer ring member and the housing to restrict relative rotation, allowing for assembly through engagement rather than welding, thereby eliminating the need for a welding process and reducing manufacturing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to attach the output-side outer ring member to the housing, then strong connection is achieved, but distortion occurs and manufacturing complexity increases

Engineering Contradiction:

Improveconnection strengthVSAvoiddistortion

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical engagement structure consisting of engagement protrusions and engagement grooves. This mechanical connection achieves the required connection strength without the heat-affected zone and distortion associated with welding, thereby resolving the contradiction between connection strength and manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If welding is used to attach the output-side outer ring member to the housing, then strong connection is achieved, but the number of processes increases

Engineering Contradiction:

Improveconnection strengthVSAvoidnumber of processes

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent eliminates the welding process entirely by using a mechanical engagement structure with protrusions and grooves that can be assembled through simple engagement. This reduces the manufacturing process count while maintaining connection strength, directly resolving the contradiction between connection strength and device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If engagement structures are used to attach the output-side outer ring member to the housing, then welding process is eliminated, but connection strength may be reduced

Engineering Contradiction:

Improveease of manufactureVSAvoidconnection strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The engagement protrusions and grooves are designed with curved surfaces that distribute contact stress evenly across the engagement interface. This geometric optimization ensures that the mechanical engagement structure achieves connection strength comparable to welding while maintaining the manufacturing simplicity and distortion-free assembly advantages.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS12078220B2Clutch unit

Publication Date: 2024.09.03 TOYOTA BOSHOKU KK

AI summary

Provided is a clutch unit in which an output-side outer ring member is attached to a base plate without welding. A clutch unit (100) includes an output-side clutch (60) and a housing (11) that accommodates the output-side clutch (60). The output-side clutch (60) includes an output-side outer ring member (62). The output-side outer ring member (62) and the housing (11) have an engagement protrusion (62s) and an engagement groove (11s) that engage with each other to restrict relative rotation therebetween.