Disk Carrier Roll-Forming Bridge Strength
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Solution Overview
Problem
Existing disk carriers with corrugated sheet metal toothing geometry have low engine-speed strength, leading to deformation at high speeds due to wave-like tooth arrangement, and current production methods result in inaccuracies and low production output.
Innovation Solution
A method and profile roller set for roll-forming disk carriers with a narrow, peripheral, self-contained unformed bridge between the inner and outer diameters, forming a hoop band cylinder that increases engine-speed strength, using a roll-forming or spin-forming process with adjustable cassettes and profile rollers to achieve precise toothing geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wave-like corrugated sheet metal toothing geometry is used, then the manufacturing process is simple, but the engine-speed strength is low and the part stretches at high speeds
Solution Approach 1:
The patent applies local quality by creating a differentiated structure where the bridge region maintains different properties than the toothing regions. The bridge is left unformed or minimally formed while the toothing areas receive full forming, creating local structural variations that optimize both strength and manufacturing efficiency
Solution Approach 2:
The toothing is segmented into multiple individual teeth rather than a continuous wave pattern. This segmentation allows each tooth to be independently formed while maintaining a distinct bridge region, improving engine-speed strength through better load distribution while retaining manufacturing simplicity
2Productivity
If extrusion process is used to produce disk carrier with hoop band, then production output is high, but manufacturing precision is low due to material anisotropy and springback
Solution Approach 1:
The bridge region is prepared in advance by leaving it unformed or minimally formed during the roll-forming process, rather than forming it afterward. This preliminary action prevents springback issues and maintains dimensional accuracy while allowing high production output through continuous roll-forming
Solution Approach 2:
Instead of forming the entire component including the bridge region and then correcting distortions, the invention inverts the approach by deliberately leaving the bridge unformed during the primary forming process. This eliminates the springback problem entirely while maintaining high productivity
3Stability of the object's composition
If the bridge region is formed with toothing, then the structural continuity is improved, but the engine-speed strength decreases due to loss of axial rigidity
Solution Approach 1:
The patent applies local quality by creating a differentiated structure where the bridge region maintains different properties than the toothing regions. The bridge is left unformed or minimally formed while the toothing areas receive full forming, creating local structural variations that optimize both strength and manufacturing efficiency
Solution Approach 2:
The forming action is extracted or removed from the bridge region while being applied to the toothing regions. This selective extraction of the forming process preserves axial rigidity in the bridge while still providing the structural benefits of toothing in the appropriate areas
4Strength
If wall thickness is increased to improve engine-speed strength, then the strength increases, but the production output decreases and material usage increases
Solution Approach 1:
The patent applies local quality by creating a differentiated structure where the bridge region maintains different properties than the toothing regions. The bridge is left unformed or minimally formed while the toothing areas receive full forming, creating local structural variations that optimize both strength and manufacturing efficiency
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 method achieves higher engine-speed strength and dimensional accuracy, allowing disk carriers to operate at higher speeds with reduced wall thickness and increased production output, minimizing material anisotropy-induced deformations.
Implementation Method 1
cassettes having profile rollers in their interior spaces, which roll out with their outer circumference the outer periphery of a component to be formed and therefore impart toothing to the component to be formed
Implementation Method 2
The bridge is arranged in the toothing as an integrated hoop band cylinder, intended to increase the engine-speed strength of the disk carrier... reduce flaring at high speeds
Data Source
AI summary
A method for roll-forming disk carriers or the like, which are designed as a pot-shaped sheet metal part having inner and outer teeth, wherein a multitude of cassettes is equidistantly arranged on the circumference of a roll-forming tool, said cassettes having profile rollers arranged in their interior, which roll out the disk carrier to be formed with their outer circumference and thus impart toothing on the disk carrier to be formed, wherein the forming depth of the profile rollers at the disk carrier to be formed is designed in such a way that a narrow, peripheral, self-contained, unformed bridge remains between the inner diameter and the outer diameter of the toothing, wherein the bridge increases the engine-speed strength of the disk carrier as a hoop band cylinder that is integrated into the toothing.