Symmetrical Conical Spring Washer for Error-Proof Transmission Assembly
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Solution Overview
Problem
Conventional conical spring washers in transmission assemblies are prone to improper installation, leading to misalignment and potential damage due to lack of preventative measures, causing uneven wear and potential failure of components.
Innovation Solution
A symmetrical conical spring washer design featuring radially aligned inner and outer tabs with alternating concave and convex orientations, allowing flexible coupling and installation in any direction to prevent misalignment and ensure proper assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conical spring washers are installed in a specific direction, then proper assembly is ensured, but the risk of mis-assembly and improper installation remains high due to lack of preventative measures
Solution Approach 1:
The washer design incorporates asymmetric features including a keyway and non-uniform tab distribution (inner tabs and outer tabs with different orientations). These asymmetric elements create a unique orientation that only fits correctly in one direction, preventing mis-assembly while maintaining ease of installation through clear orientation cues.
Solution Approach 2:
The patent employs visual differentiation through the asymmetric arrangement of tabs and keyways that create distinct orientation indicators. The concave and convex orientations of tabs provide visual cues similar to color coding, allowing installers to quickly identify the correct installation direction without complex procedures.
2Device complexity
If conventional washers are used without preventative measures, then device complexity is reduced, but the risk of washer movement into undesirable locations increases
Solution Approach 1:
The washer is segmented into multiple functional elements: inner tabs, outer tabs, keyways, and intermediate portions. This segmentation allows each element to serve a specific purpose in preventing washer movement and ensuring proper positioning, thereby improving reliability without significantly increasing overall complexity.
Solution Approach 2:
The washer incorporates flexible tab elements that can deform elastically during installation and operation. These flexible tabs engage with corresponding features on adjacent components to prevent washer movement into undesirable locations, providing position stability through mechanical engagement rather than complex constraints.
3Productivity
If conventional washers are improperly installed, then assembly time is reduced, but uneven wear and potential damage to components occurs
Solution Approach 1:
The washer design incorporates preliminary anti-action through asymmetric features and orientation indicators that prevent incorrect installation before it can cause damage. The keyway and tab arrangement create mechanical interference that blocks mis-assembly, ensuring that only properly oriented washers can be installed, thereby eliminating the harmful effects of improper installation.
Solution Approach 2:
The washer design is self-checking through its asymmetric geometry. The correct orientation is automatically indicated by the alignment of tabs and keyways, allowing the washer to guide its own proper installation without requiring external verification or complex assembly procedures, thus maintaining high assembly speed while preventing damage.
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 symmetrical design ensures proper installation and operation by preventing the washer from falling into gaps, reducing wear and damage, and maintaining assembly integrity regardless of orientation, thus enhancing the reliability and longevity of transmission components.
Implementation Method 1
the plurality of inner tabs and plurality of outer tabs are flexibly coupled to the intermediate portion
Data Source
AI summary
A conical spring washer includes a symmetrical annular body, a plurality of inner tabs and a plurality of outer tabs formed in the body. Each of the plurality of inner tabs has a width that tapers radially inwardly. Each of the plurality of outer tabs has a maximum width that is greater than a maximum width of each of the plurality of inner tabs. An intermediate portion is defined in the body and disposed between the plurality of inner tabs and plurality of outer tabs. The plurality of inner tabs and plurality of outer tabs are flexibly coupled to the intermediate portion.