Freewheel Clutch Coupling Structure for Compact Torque Transmission
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Solution Overview
Problem
Existing freewheel devices and clutches face challenges in cost-effectively securing the coupling element to the first freewheel component and designing the spring element to be both reliable and space-saving.
Innovation Solution
A freewheel device with a coupling element made of punched sheet metal and a mirror-symmetrical spring element, comprising rectilinear wire portions and a fastening portion, allows secure and cost-effective fixation to the first freewheel component, enabling a switchable torque transmission mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional coupling elements and spring elements are used in freewheel devices, then the coupling element can be secured to the first freewheel component, but the cost-effectiveness and space utilization are insufficient
Solution Approach 1:
The coupling element is segmented into a multi-part structure comprising a head portion, a leg portion, and a retaining portion. This segmentation allows each part to perform its specific function efficiently while reducing overall complexity and manufacturing cost. The head portion engages with the second freewheel component, the leg portion provides structural support, and the retaining portion secures the element in place, achieving reliable fixation through functional decomposition.
Solution Approach 2:
The coupling element is designed as a simple punched component that can be manufactured cost-effectively using sheet metal punching processes. The design prioritizes ease of manufacture and assembly over long service life, allowing for economical production while maintaining sufficient reliability for the application. The spring element similarly uses a simple wire construction that can be quickly formed and assembled.
2Ease of manufacture
If conventional spring elements are used in freewheel devices, then the spring force can be provided, but the space utilization and cost-effectiveness are insufficient
Solution Approach 1:
The spring element utilizes curved wire geometry with specific radii of curvature to provide the necessary spring force. The wire is formed into arcs and curves that efficiently store and release mechanical energy, maximizing the spring effect within minimal space. The curved configuration allows the spring element to fit within the compact constraints of the freewheel device while maintaining adequate force characteristics.
Solution Approach 2:
The spring element is constructed from a thin wire that is bent and formed into a flexible structure. This wire-based spring acts as a flexible element that can deform elastically to provide the required spring force. The thin-wire construction minimizes material usage and occupied volume while maintaining the necessary mechanical properties through careful design of the wire path and curvature.
3Reliability
If the coupling element is secured to the first freewheel component, then torque transmission can be enabled, but the manufacturing complexity increases
Solution Approach 1:
The coupling element merges multiple functions into a single integrated component. The head portion, leg portion, and retaining portion are formed as one piece that simultaneously provides engagement, structural support, and retention functions. This merging eliminates the need for separate fasteners, springs, or retaining mechanisms, thereby reducing assembly complexity while ensuring reliable torque transmission through the unified structure.
Solution Approach 2:
The coupling element is designed as a multi-functional component that performs several roles: it transmits torque from the first to the second freewheel component, provides structural connection, and secures itself in position through its retaining portion. The spring element similarly serves multiple purposes by providing both the spring force for engagement and the flexible connection for torque transmission. This multi-functionality reduces the total number of parts and simplifies the overall device structure.
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 solution provides a cost-effective, reliable, and space-saving freewheel device with improved torque transmission capabilities, allowing for efficient and compact integration in vehicle drive trains.
Implementation Method 1
The spring element (32) is supported by a spring force of the spring element (32)
Data Source
AI summary
A freewheel device having a first freewheel component and a second freewheel component which is axially coupled to the first freewheel component via an axially effective coupling device. When there is relative rotation between the first and second freewheel component in a first rotational direction, it connects the two components together for conjoint rotation and, when there is relative rotation in an opposite second rotational direction, releases the two components so that they can rotate relative to each other and which has at least one coupling element which is subjected to a spring force by means of a spring element. The spring element fixes the coupling element on the first freewheel component and specifies a tilting axis about which the coupling element can be tilted against the spring force.