Flywheel Clinching Without Viscoelastic Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flywheel production methods for vehicle starters suffer from noise and vibration issues due to the use of viscoelastic layers, which cause tool sticking and increased rigidity, leading to additional manufacturing steps and ineffective noise reduction.
Innovation Solution
A method involving the permanent connection of sheet metal layers without a viscoelastic layer through clinching, forming a double sheet metal structure that absorbs vibrations and noise across the entire surface, reducing resonance noises and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a viscoelastic damping layer is used between sheet metal layers, then noise and vibration damping is achieved, but tool adhesion occurs and manufacturing complexity increases
Solution Approach 1:
The invention removes the viscoelastic damping layer from the sandwich structure, extracting the problematic element that caused tool adhesion and manufacturing complexity while retaining the essential noise and vibration damping function through the clinched sheet metal structure itself
Solution Approach 2:
The invention replaces the viscoelastic material-based damping mechanism with a mechanical damping mechanism achieved through the clinched connection of sheet metal layers, where the deformed metal structure provides vibration absorption without the adhesion problems of viscoelastic materials
2Object-affected harmful factors
If a viscoelastic layer is inserted between sheet metal layers, then damping is provided, but the stiffness of the sandwich component increases detrimentally
Solution Approach 1:
The invention changes the physical parameters of the damping structure by using thin sheet metal layers with specific thickness ratios (first layer 0.5-2.0mm, second layer 0.3-1.5mm) and specific clinching deformation parameters to achieve vibration damping while maintaining low stiffness and flexibility
3Object-affected harmful factors
If separate damping plate components are manufactured and joined, then noise reduction is achieved, but manufacturing time and effort increase
Solution Approach 1:
The invention merges the damping function directly into the flywheel structure by clinching the sheet metal layers together in the final assembly process, eliminating the need for separate damping plate components and their associated manufacturing and assembly steps
Solution Approach 2:
The sheet metal layers are prepared in advance with appropriate dimensions and are positioned on the flywheel before the clinching process, allowing the damping structure to be formed as an integrated part of the final assembly rather than requiring separate pre-manufactured damping components
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 approach effectively reduces noise and vibration, decreases the load on engine components, and simplifies the manufacturing process by eliminating the need for separate sound-damping sheets, resulting in a lighter, more flexible flywheel with improved acoustic properties.
Implementation Method 1
a contact pressure, which depends on the respective material of the sheet layers and their material thickness, is exerted on the sheet layers to be joined and the two sheet layers are deformed and fixed to each other by clinching
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a method for producing a flywheel, in which a damping plate part is produced by permanently connecting at least a first metallic plate element (13) provided for the flywheel to at least one further material layer (14) to form a sandwich component, wherein, according to the invention, the first plate element (13) is connected by a joining process to at least a second, parallel plate layer (14), so that they lie on one another without an intermediate viscoelastic layer, to form a disc-shaped structural unit (11). It is thereby possible to produce a flywheel (10) which has vibration-damping and noise-damping properties. These flywheels are advantageous in particular for starters in vehicles having start/stop devices, since frequent start-up processes occur there.