Decoupler With Free Wheel System And Vibration Damping
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Solution Overview
Problem
Existing decoupler systems for alternators in vehicles face issues with high wear due to friction, require strong and costly materials, suffer from grease leakage, and lack a fail-safe mechanism to continue operating in case of spring failure, while also being unable to simultaneously provide free wheel and vibration damping functions with lightweight pulleys.
Innovation Solution
A decoupler design featuring a pulley with a torsion spring and clutch spring arrangement that allows for free wheel operation and vibration damping, using lightweight materials, incorporating a fail-safe mechanism with a stop washer to lock hub pieces in case of overload, and a containment wall to prevent grease leakage, enabling operation as both a decoupler and one-way clutch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If friction contact between clutch spring and pulley inner race is used for torque transmission, then torque transmission function is achieved, but high wear and component damage occur
Solution Approach 1:
A friction element is introduced as an intermediary component between the clutch spring and the pulley inner race. This friction element absorbs the wear and friction effects, allowing the clutch spring to transmit torque effectively while the friction element can be replaced without damaging the pulley or other critical components.
Solution Approach 2:
The friction element is designed as a consumable, replaceable component that can withstand high wear. When worn out, it can be replaced without replacing the entire pulley or clutch assembly, reducing maintenance costs and extending the life of critical components.
2Strength
If strong resistant materials and heat treatment are used for pulley inner race to support high stress, then component strength is improved, but weight and cost increase
Solution Approach 1:
The friction element serves as a mediator that protects the pulley inner race from direct high-stress contact. This allows the pulley to be made from lighter, less expensive materials while still withstanding the operational stresses through the protective friction element.
Solution Approach 2:
Instead of making the pulley inner race from expensive, heavy high-strength materials, a cheaper, lighter friction element is used that can be replaced when worn. This reduces the weight and cost of the pulley while maintaining system durability.
3Object-affected harmful factors
If large torsion spring is used for vibration damping, then vibration damping effect is improved, but device complexity and space requirements increase
Solution Approach 1:
The torsion spring is positioned within the existing clutch spring assembly, utilizing the internal space of the clutch spring. This nested arrangement allows the torsion spring to provide vibration damping without significantly increasing the overall size or complexity of the decoupler mechanism.
Solution Approach 2:
The clutch spring assembly serves multiple functions: it provides torque transmission through friction contact and simultaneously houses the torsion spring for vibration damping. This multi-functionality reduces the need for separate components and simplifies the overall device structure.
4Ease of operation
If conventional decoupler design is used, then free wheel operation is achieved, but fail-safe mechanism and grease containment are lacking
Solution Approach 1:
A fail-safe mechanism is incorporated that activates when the torsion spring fails. This mechanism includes a backup friction element and containment structures that prevent grease leakage and maintain operational capability even after spring failure, providing protection before complete system failure occurs.
Solution Approach 2:
The friction element serves dual purposes: it enables free wheel operation during normal operation and acts as a fail-safe mechanism when the torsion spring fails. Additionally, containment walls integrated into the pulley structure prevent grease leakage under both normal and failure conditions.
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 reduces wear, allows for the use of lighter and less expensive materials, minimizes grease leakage, and ensures continued operation even if the torsion spring fails, while providing efficient torque transmission and vibration damping.
Implementation Method 1
a spring that provides isolation between the hub and the shaft. The decoupler provides damping at a preset value between the hub and the pulley
Implementation Method 2
a friction contact between the clutch spring and the inner surface of the pulley is required so that the driving shaft is coupled to the driven shaft
Data Source
AI summary
The present invention relates to a decoupler with free wheel system and comprising a vibration damping pulley, a shaft actionable by the pulley, hub pieces having a first hub piece and a second hub piece, hub pieces being mounted between the inner race of the pulley and the outer surface of the shaft, at least one journal element between the shaft and pulley, along with a torsion spring, and a clutch spring, with the first hub piece being mounted on the shaft and the second hub piece being mounted around the shaft and can rotate relative to it, the torsion spring being disposed between the outer race of the hub pieces and the inner race of pulley, having a first end operatively attachable to the pulley and a second end operatively attachable to the second hub piece and the clutch spring being disposed internally in relation to the torsion spring and which is frictionally engaged with the hub pieces for transmission of torque to the shaft.