Coupling System Axial Plug Connection Noise Reduction
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Solution Overview
Problem
Existing clutch units often experience noise issues, such as rattling, due to torsional backlash in the drive connection between engine and transmission sub-units, and require complex and costly assembly methods.
Innovation Solution
A clutch unit with an axial plug-in connection featuring interlocking profiles and counter-profiles with radial and circumferential bracing, utilizing preloaded compression springs and a locking ring for secure engagement, ensuring a play-free and torsionally elastic connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a rigid drive connection is used to eliminate torsional backlash and noise, then noise elimination is improved, but assembly complexity increases
Solution Approach 1:
The drive connection is segmented into multiple components: a first component with an inner profile, a second component with an outer profile, and a retaining element. These segmented parts can be assembled separately and then connected through the axial plug connection, simplifying the overall assembly process while achieving the rigid connection needed to eliminate noise
Solution Approach 2:
The retaining element acts as an intermediary component that facilitates the connection between the first and second components. It enables the axial plug connection to be formed easily during assembly by guiding the engagement of the interlocking profiles, thereby reducing assembly complexity while maintaining the noise-free rigid connection
2Reliability
If a complex assembly method is used to ensure reliable drive connection, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The interlocking profiles are designed to automatically engage and secure the components together during the axial plug connection assembly process. The geometry of the profiles themselves provides the locking mechanism, eliminating the need for additional complex fastening operations or specialized assembly tools, thereby reducing manufacturing cost while ensuring reliable connection
Solution Approach 2:
The profile geometry is optimized with specific geometric parameters that enable reliable engagement through the axial plug connection. By carefully designing the shape, size, and orientation of the interlocking features, the connection achieves high reliability through simple assembly operations, reducing manufacturing complexity and cost
3Ease of operation
If clearance is provided in the drive connection to facilitate assembly, then ease of assembly is improved, but torsional play increases causing noise
Solution Approach 1:
The connection transitions from a static clearance-based fit to a dynamic interlocking engagement. During assembly, the components are inserted with minimal clearance for ease of insertion, but once engaged, the interlocking profiles create a rigid torsional connection that eliminates play. The retaining element ensures proper alignment and engagement, achieving both ease of assembly and noise-free operation
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 solution effectively eliminates noise by providing a torsionally rigid connection with minimal play, facilitating easy and cost-effective assembly while maintaining torque transmission efficiency.
Implementation Method 1
at least some of the profiles forming the profiles and/or counter-profiles can consist of two components with toothed sections, the toothed sections being clamped circumferentially on a mating toothed section (counter-profiles and/or profiles). This ensures virtually backlash-free engagement between the corresponding profiles. Due to the clamping between the two components, a certain degree of torsional elasticity can also be achieved between the profiles and counter-profiles. The torsional stiffness of this elastic tension depends on the force applied by at least one energy storage device clamping the two components, such as a helical compression spring.
Data Source
Figure 1~4a
AI summary
The invention relates to a coupling unit or coupling system made up of at least two sub-units, one sub-unit is pre-assembled on the engine side, namely on the output shaft from the engine and the other sub-unit is pre-assembled on the gearbox side.