Convex Insertion Contour for Load Ring Assembly
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Solution Overview
Problem
The assembly of a diaphragm spring-actuated friction clutch release device is labor-intensive and error-prone due to the high force required to push a load ring onto its carrier element, which is exacerbated by the radial deformation state and contour design.
Innovation Solution
The insertion contour is designed with a convex continuous curve that decreases in slope in the sliding direction of the load ring, allowing for easier assembly by reducing the axial force needed, particularly in the rear part of the deformation area where significant radial deformation occurs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the load ring is pushed onto the insertion contour with a conventional linear deformation section, then the assembly process is simple in design, but the required assembly force is excessively high making the process exhausting and error-prone
Solution Approach 1:
The deformation section is designed with a convex contour line that curves outward in the axial direction, replacing a linear or concave profile. This curvature allows the load ring to gradually deform and expand onto the insertion contour, distributing the deformation force over a longer axial distance and reducing the peak assembly force required.
Solution Approach 2:
The slope of the contour line in the deformation section is specifically optimized to decrease in the axial mounting direction. By controlling the geometric parameters of the contour line (its convex shape and slope progression), the patent transforms the force distribution during assembly, reducing the maximum force needed while maintaining effective load ring deformation.
2Force
If the contour line slope is increased to reduce assembly force in the deformation area, then the required assembly force decreases, but the axial length of the insertion contour increases
Solution Approach 1:
The convex contour line creates an optimized deformation path that achieves effective load ring expansion over a controlled axial distance. The curvature allows force reduction without requiring excessive axial length, as the convex shape efficiently transitions the load ring from its initial state to the expanded state on the insertion contour.
Solution Approach 2:
The slope of the contour line is specifically designed to decrease in the axial mounting direction, creating an optimized balance between force reduction and axial length control. This parameter optimization ensures that the deformation section achieves its force-reducing effect while maintaining an axially short overall length of the release device.
3Ease of manufacture
If a linear deformation section is used, then the manufacturing process is simple, but the assembly process becomes exhausting and error-prone due to high forces
Solution Approach 1:
The convex contour line with decreasing slope in the axial direction can be manufactured using standard machining or forming processes. While slightly more complex than a linear section, the convex profile remains manufacturable and provides significant benefits by reducing assembly force requirements, making the overall process less exhausting and error-prone.
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 design simplifies the assembly process by reducing the maximum required assembly force, making it less exhausting and error-prone for personnel while maintaining an axially short overall length.
Implementation Method 1
an elastically radially deformable load ring (24), which is designed to be pushed on in the axial direction onto an insertion contour (48) of the axial extension (22)
Data Source
Figure 1
Figure 2
AI summary
The device has a radial elastic deformable load ring (24) staying in bearing contact with abutment contours. An influx contact (48) includes a deforming section (48b) for the ring that extends to the influx contour from an axial starting position (P) to an end position in a ring groove (19). An associated contact diameter (DP) corresponding to effective diameter of the ring in a starting position and another contact diameter (DQ) reaches an extreme value in the end position. The deforming section includes a contour line (49) whose rise is decreased in sliding direction of the ring.