CVT Metal Element Projection Structure for Locking Edge Thickness
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Solution Overview
Problem
In continuously variable transmissions, the existing manufacturing methods for metal elements result in an imbalance in thickness between the locking edge and ear section, leading to reduced transmission efficiency due to bending and polishing issues.
Innovation Solution
A metal element design with a projection section on the back surface of the body section, positioned behind the locking edge, and a mold configuration that shapes this projection to ensure contact and balance thickness, including a main punch and counter punch that create space for material flow and reduce pressing load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the locking edge is excessively polished during barrel polishing, then the flat ear section is less affected, but the thickness of the locking edge becomes smaller than the thickness of the ear section
Solution Approach 1:
The patent applies local quality by creating a projection section at a specific location on the locking edge that is designed to compensate for excessive polishing. This projection section is positioned to ensure that even after barrel polishing removes material, the locking edge maintains sufficient thickness. The projection section is formed with specific dimensions (extending in the right-left direction with a length of 0.5-2.0mm) to locally counteract the polishing effect without affecting the overall geometry of the metal element.
2Productivity
If the locking edge thickness is reduced due to polishing, then the manufacturing process is simplified, but the chord of the metal belt bends and transmission efficiency is reduced
Solution Approach 1:
The patent applies preliminary action by forming the projection section on the locking edge before the barrel polishing process. This projection section is created during the punching process using a mold with a specific configuration (a radially outer end surface of a front surface of the body section). The projection section is formed in advance to compensate for the material that will be removed during polishing, ensuring that the locking edge maintains adequate thickness for proper function after polishing is complete.
3Strength
If the position of the locking edge coincides with the front edge of the saddle surface, then the structural integrity is improved, but the bending load on the neck section increases
Solution Approach 1:
The patent applies asymmetry by creating an asymmetric geometry on the locking edge through the projection section. The projection section breaks the symmetry of the locking edge, creating an uneven surface profile that is specifically designed to reduce bending loads. The projection section extends in the right-left direction and creates an asymmetric load distribution that reduces the bending moment on the neck section while maintaining the structural integrity of the overall metal element structure.
Data Source
AI summary
A metal element, which is pressed and punched by a mold, includes: a neck section positioned between a pair of right and left ring slots; an ear section continuous to a radially outer side of the neck section; and a body section continuous to a radially inner side of the neck section. A locking edge extending in a right-left direction is formed at a radially outer end of the front surface of the body section, and the metal element includes a projection section extending in the right-left direction on a back surface of the body section at a position backward of the locking edge.