Dual Clutch Alignment Under Simulated Operating Load
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Solution Overview
Problem
Traditional methods for aligning dual clutches in continuously variable transmissions, such as those in snowmobiles, are insufficient due to modern design changes like increased torque and altered motor mounts, which require a more accurate alignment under load conditions to ensure optimal belt life and performance.
Innovation Solution
An apparatus comprising a clutch pre-loader with a clutch ring and tensioner to simulate operating loads, combined with an alignment bar and center-to-center measuring tool, allows users to measure and adjust clutch positions for optimal alignment under normal operating conditions, using conventional shimming techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional alignment methods are used (aligning clutches at rest without load), then the alignment process is simple, but the alignment is inaccurate under modern operating conditions with increased torque and altered motor mounts
Solution Approach 1:
The patent applies preliminary action by pre-loading the clutch assembly with a spring mechanism before final alignment is established. The spring pre-loader applies downward force on the secondary clutch, simulating operating conditions and allowing the clutches to be aligned in a loaded state rather than at rest. This ensures the alignment is accurate under modern high-torque conditions while maintaining a systematic alignment process
Solution Approach 2:
The patent changes the loading parameter from zero-load (traditional method) to simulated operating load (using spring pre-loader). By introducing a controlled spring force that mimics actual operating torque conditions, the alignment process accounts for modern motor torque increases and altered motor mount positions, achieving accurate alignment under real operating conditions rather than idealized at-rest conditions
2Loss of time
If clutches are aligned at rest without load, then the alignment procedure is quick and easy, but heat and slippage increase during operation due to misalignment
Solution Approach 1:
The spring pre-loader applies preliminary load to the clutch assembly during the alignment process, simulating operating conditions. This allows the belt and clutches to be aligned while under simulated load, preventing the misalignment that would otherwise cause heat and slippage during operation. The alignment is established in advance under conditions that match actual operation
Solution Approach 2:
The patent provides beforehand cushioning by using the spring pre-loader to compensate for alignment errors before operation begins. The spring mechanism allows for fine adjustment and maintains optimal alignment under load, preventing the harmful effects of misalignment (heat and slippage) from occurring during operation rather than correcting them after the fact
3Power
If modern motor designs with increased torque are used, then power output is improved, but traditional alignment methods become insufficient and clutch misalignment occurs
Solution Approach 1:
The patent changes the alignment condition parameter from at-rest to under-load by introducing the spring pre-loader. This allows the alignment to be established under simulated operating conditions that match the increased torque of modern motors, ensuring the alignment remains stable and reliable when the motor delivers its higher power output
Solution Approach 2:
The patent introduces dynamics by using a spring-based pre-loader that can accommodate variations in motor mount positions and clutch positions under load. The spring mechanism provides flexible, adjustable loading that adapts to the specific operating conditions of modern high-torque motors, maintaining reliable alignment despite the increased forces involved
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 solution enables precise alignment of clutches under simulated load conditions, reducing heat and slippage, and improving performance by allowing for adjustments that maintain optimal alignment during normal operation.
Implementation Method 1
A spring is inserted into the tensioner and a preload fastener is used to apply a load to the clutch assembly
Implementation Method 2
The measuring tool is inserted into the alignment bar and down onto the secondary clutch to measure the vertical position of the secondary clutch
Data Source
AI summary
A clutch alignment apparatus and method of aligning a dual clutch system in a continuously variable transmission that enables a user to measure the alignment of the primary clutch and secondary clutch when the system is under a load that is similar to that which is applied when the system is operating under normal operating conditions.