Two-Piece FEAD Pulley Insert for Vibration Noise Reduction
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Solution Overview
Problem
Front end accessory drive (FEAD) pulleys, particularly those in internal combustion engines, experience high levels of vibration leading to noise emission, which existing noise reduction solutions fail to adequately mitigate.
Innovation Solution
A two-piece noise reduction insert comprising a first member rotatable within the pulley and a second member that locks the first member in place, preventing rotation and thereby reducing noise transmission, utilizing a cavity and limb configuration for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a noise reduction insert is provided in a FEAD pulley to mitigate vibration and noise, then noise emission is reduced, but the insert may rotate or become dislodged during operation
Solution Approach 1:
The insert is divided into two separate members: a first member (noise reduction element) and a second member (retention element). The first member contains cavities that receive the second member, creating a modular assembly that combines noise mitigation with secure retention. This segmentation allows each component to perform its specific function while working together as an integrated solution.
Solution Approach 2:
The second member is inserted into the cavities of the first member, creating a nested configuration where one component fits within another. This nesting arrangement ensures that the retention element is securely positioned within the noise reduction element, preventing rotation or dislodgement while maintaining the compact design required for pulley integration.
2Object-affected harmful factors
If a noise reduction insert is integrated into a pulley, then noise is reduced, but insertion forces may be high causing material damage
Solution Approach 1:
By dividing the insert into two separate members that can be assembled independently, the installation process avoids high insertion forces. The first member can be installed in the pulley without excessive force, and the second member is then inserted into the cavities of the first member, distributing the assembly forces and reducing the risk of material damage.
Solution Approach 2:
The first member is prepared with pre-formed cavities before installation into the pulley. These cavities are designed to receive the second member, allowing for a staged assembly process that reduces insertion forces. The preliminary preparation of the cavities ensures proper fit and minimizes the force required during final assembly.
3Ease of operation
If the first member is rotatable within the pulley to self-lock, then ease of installation is improved, but the locking mechanism may fail to prevent rotation
Solution Approach 1:
The rotation prevention function is separated from the noise reduction function by using two distinct members. The first member provides noise reduction and can rotate during installation for self-alignment, while the second member is specifically designed to prevent rotation by engaging with the pulley structure. This segmentation allows each component to optimize its specific function.
Solution Approach 2:
The second member acts as an intermediary between the first member and the pulley structure. It transfers the rotational constraint from the pulley to the first member, ensuring that the noise reduction element remains securely positioned. The second member mediates the interaction between the rotatable first member and the fixed pulley structure.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A pulley insert for a FEAD pulley comprises a first member insertable into a pulley such that the first member is rotatable within the pulley, the first member comprising a cavity for receipt of a second member; and a second member insertable into the cavity of the first member such that, when the first member is inserted into a pulley and the second member is inserted into the cavity of the first member, the second member prevents rotation of the first member relative to the pulley.