Disconnect Clutch Return Spring Preload for High-Speed Torque Transfer
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Solution Overview
Problem
Existing disconnect clutches face challenges in maintaining torque transmission functionality at smaller diameters and higher rotational speeds, leading to increased stress and reduced service life of return springs, particularly when coupled with electric motors.
Innovation Solution
The return spring is positioned in a radially outer portion against a torque transfer component, with adjustable preload and tolerance compensation achieved through shimming and varying friction disc designs, allowing for force adjustment without additional bending pieces, thus reducing stress on the spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the diameter of the return spring is reduced to meet installation space requirements, then the installation space constraint is satisfied, but the service life of the return spring is reduced due to increased stress
Solution Approach 1:
The patent changes the geometric parameters of the return spring, specifically the diameter of the force edge, to optimize the balance between installation space and service life. By carefully selecting the spring diameter within a specific range, the design satisfies installation space constraints while maintaining acceptable stress levels and service life.
2Strength
If the force edge diameter of the return spring is kept large to maintain strength, then the service life is improved, but the installation space requirement is exceeded
Solution Approach 1:
The patent optimizes the force edge diameter parameter of the return spring to achieve the best compromise between strength and installation space. The specific parameter range is determined through calculation and experimentation to ensure both requirements are met.
3Reliability
If the return spring force is increased to overcome force hysteresis and meet dynamic requirements, then the reliability is improved, but the stress on the spring increases reducing its service life
Solution Approach 1:
The patent optimizes the force parameters of the return spring, including the preload force and the force during engagement, to achieve the minimum necessary force for reliable operation while avoiding excessive forces that would reduce service life. The force edge diameter and spring stiffness are adjusted to achieve optimal force characteristics.
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 solution enhances the service life of the return spring by maintaining a constant minimum force while accommodating geometric tolerances, ensuring efficient torque transmission at high rotational speeds without exceeding installation space constraints.
Implementation Method 1
an application element, for example in the form of a pad or lever, is provided to axially displace at least one of the friction discs for a frictional connection. The application element is in contact with a return spring, which is provided to release the frictional connection.
Data Source
AI summary
A disconnect clutch for a drive train of a motor vehicle includes a torque transfer component with a contact region, an outer disc carrier, an application element, and a return spring. The outer disc carrier is rotationally and axially fixed on the torque transfer component, and arranged for receiving rotationally fixed and axially displaceable friction discs arranged for torque transmission with counter friction discs. The application element is for axially displacing at least one of the friction discs for a frictional connection and the return spring is for releasing the frictional connection. The return spring contacts the application element, the return spring comprises a radially outer portion that bears against the contact region, and the contact region is designed to modify a preload of the return spring.