CVT Metal Element Pressing for Uniform Plate Thickness
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Solution Overview
Problem
The existing methods for manufacturing metal elements for continuously variable transmission often result in uneven plate thickness, leading to reduced transmission efficiency due to differences in thickness at the chord portion of the metal belt, which affects the alignment and contact between metal elements around the pulleys.
Innovation Solution
A method involving press processing and punching of a band plate-shaped metal element material using a metal mold with protrusion portions that form recessed areas, allowing for the adjustment of plate thickness by extruding material to create bulging portions, thereby balancing thickness inside and outside the radial direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press processing is performed with a conventional metal mold, then the metal element is manufactured efficiently, but the plate thickness becomes uneven and the ear portion plate becomes larger than the body portion plate thickness
Solution Approach 1:
The patent applies local quality by creating a recessed portion at a specific location on the metal element (the ear portion) through a protrusion portion on the main punch. This localized modification allows the plate thickness to be adjusted specifically where needed, making the ear portion plate thickness match the body portion plate thickness, thereby resolving the uneven thickness issue without affecting other areas of the metal element
Solution Approach 2:
The patent employs preliminary action by forming the recessed portion during the press processing step itself, before the metal elements are assembled into the metal belt. The protrusion portion on the main punch creates the recessed portion in advance, ensuring that the plate thickness is corrected before the elements are brought into close contact and before any bending or wear issues can occur
2Shape
If the plate thickness is uneven with the ear portion being thicker, then the metal element structure is formed, but the chord portion of the metal belt bends when metal elements are brought into close contact, reducing transmission efficiency
Solution Approach 1:
The patent applies local quality by creating a recessed portion at a specific location on the metal element (the ear portion) through a protrusion portion on the main punch. This localized modification allows the plate thickness to be adjusted specifically where needed, making the ear portion plate thickness match the body portion plate thickness, thereby resolving the uneven thickness issue without affecting other areas of the metal element
Solution Approach 2:
The patent converts the potential harm of uneven plate thickness into a benefit by deliberately creating a recessed portion in the ear portion. This recessed portion, which might seem like a defect, actually serves to equalize the plate thickness between the ear portion and body portion, preventing bending and maintaining transmission efficiency when the metal belt is in operation
3Ease of manufacture
If the metal mold is used for pressing, then the metal element is manufactured, but the load on the metal mold increases and durability is reduced
Solution Approach 1:
The patent applies local quality by creating a recessed portion at a specific location on the metal element (the ear portion) through a protrusion portion on the main punch. This localized modification allows the plate thickness to be adjusted specifically where needed, making the ear portion plate thickness match the body portion plate thickness, thereby resolving the uneven thickness issue without affecting other areas of the metal element
Solution Approach 2:
The patent employs parameter changes by modifying the geometry of the main punch to include a protrusion portion. This changes the pressing parameters locally, creating a recessed portion that equalizes plate thickness. By adjusting the pressing parameters in this way, the process achieves better thickness uniformity with reduced load on the metal mold, extending its durability
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 method ensures balanced plate thickness, reduces the load on the metal mold, and improves durability by allowing for precise adjustment of the bulging portions, enhancing the transmission efficiency by minimizing bending and wear at the neck portion.
Implementation Method 1
a bulging portion bulging in the longitudinal (front-rear) direction from the radial direction inner edge of the ear portion or the radial direction outer edge of the body portion is formed by the material extruded from the recessed portion by the protrusion portion
Data Source
AI summary
A method for manufacturing a metal element includes performing press processing and punching processing on a band plate-shaped metal element material having a constant cross section by a mold with a main punch in contact with a rear surface of the metal element and a counter punch in contact with the front surface thereof. The main punch or the counter punch has protrusion portions which are in contact with at least a part of the ear portion or the body portion to form a recessed portion, and a bulging portion bulging in the longitudinal direction from the radial direction inner edge of ear portions of the metal element or the radial direction outer edge of a body portion thereof, which is formed by the material extruded from the recessed portion by the protrusion portion.