Diecast Coupling Member Machined Pocket Plate
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Solution Overview
Problem
Existing methods for forming pocket plates in one-way ratcheting type coupling or clutch assemblies, such as powdered metal parts, are costly and lack efficient solutions for improving performance during overrun conditions.
Innovation Solution
A diecast coupling member with a machined surface portion, specifically an annular pocket plate formed from a diecasting process using a non-ferrous alloy like aluminum silicon, where the surface portions are angled slightly positive or negative to enhance performance during overrun, and a method for manufacturing this unitary pocket plate with machining to improve retention of locking members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If powdered ferrous metals are used to form pocket plates, then manufacturing precision and strength can be achieved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from powdered ferrous metal to diecast aluminum alloy, and changes the forming process parameter from powder metallurgy to diecasting. This parameter change achieves comparable manufacturing precision while significantly reducing manufacturing cost and material weight
Solution Approach 2:
The patent uses composite material structure by incorporating particles of strengthening alloying material (such as silicon particles) into the diecast aluminum alloy base portion, creating a composite material that provides both the cost advantage of diecasting and the strength requirements of the pocket plate application
2Ease of manufacture
If diecasting process is used to form pocket plates, then manufacturing cost is reduced, but surface quality and performance during overrun conditions deteriorate
Solution Approach 1:
The patent applies preliminary action by machining the surface portions of the pockets before final assembly. This preliminary machining action corrects the surface quality issues inherent in diecasting and optimizes the pocket surfaces for proper locking member retention and overrun performance
Solution Approach 2:
The patent applies local quality by selectively machining only the surface portions of the pockets that contact the locking members, while leaving the bulk diecast structure intact. This localized treatment improves reliability at the critical contact surfaces without compromising the cost advantages of diecasting for the overall part
3Ease of operation
If locking members move freely in pockets during overrun, then operational flexibility is improved, but retention and stability deteriorate
Solution Approach 1:
The patent changes the geometric parameter of the pocket surface portions by machining them to specific angles and profiles. This parameter change creates optimal retention characteristics that maintain locking member stability during overrun while allowing necessary operational mobility
Solution Approach 2:
The patent applies curvature principles by designing the pocket surface portions with specific curved profiles and angles. The machined surface portions feature curved geometries that guide locking member movement and enhance retention through geometric constraints that maintain stability during dynamic overrun conditions
Data Source
Figure 1a~2
Figure 3
Figure 4a~4b
AI summary
A diecast pocket plate or coupling member including a pocket with a machined surface layer or portion, a method for making the coupling member and an overrunning clutch assembly including the coupling member are provided. The member is formed as a unitary diecasting from a die-casting material in a die-casting process. The diecast member includes a coupling face having at least one pocket which is sized and shaped to receive and retain a locking member that moves in the pocket during an overrun condition of the assembly. The pocket is defined by a plurality of surface portions including an angled, slightly positive surface portion which is machined vertical or slightly negative to improve performance of the assembly during the overrun condition.