Deep-Drawn Freewheel Flange With Centering Collar for Easier Assembly
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Solution Overview
Problem
Existing freewheel assemblies require high effort for installation due to complex connections with other components, which complicates the assembly process.
Innovation Solution
A centering collar is added to the flange's disk portion, projecting radially outward, simplifying assembly by forming a radial bearing surface and allowing for deep drawing production, with multiple through holes for improved accessibility and a compact axial design, enabling a press fit connection with the sleeve portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a centering collar is added to the flange to simplify assembly and provide a radial bearing surface, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The centering collar is integrated directly into the deep-drawn flange as a unified component rather than being a separate part. This merging approach simplifies assembly by providing a built-in radial bearing surface and centering function, while avoiding the complexity of additional separate components and their associated assembly steps.
Solution Approach 2:
The deep-drawn flange serves multiple functions: it provides structural support, enables press-fit connection of the outer ring via its sleeve portion, and provides centering and bearing functionality through the integrated centering collar. This multi-functionality reduces the need for separate components, simplifying overall assembly.
2Ease of operation
If multiple through holes are added to the disk portion for improved accessibility during assembly, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The through holes are pre-formed as integral features of the deep-drawn flange during the stamping process. This preliminary action ensures precise positioning and uniform distribution of the holes before assembly, eliminating the need for subsequent drilling or tapping operations and reducing precision requirements for later assembly steps.
3Volume of moving object
If the outer ring is made with the same axial length as the sleeve portion for compact design, then volume is reduced, but manufacturing difficulty increases
Solution Approach 1:
The outer ring and sleeve portion are designed with matching axial lengths and are connected through a press-fit interface. This merging of dimensions creates a compact axial profile while the press-fit connection method maintains manufacturing simplicity by using a straightforward interference fit process without requiring complex joining operations.
Data Source
AI summary
A freewheel assembly includes a central axis of rotation, a single-piece flange formed by deep drawing, and a freewheel unit. The single-piece flange includes a sleeve portion, a disk portion protruding radially outward from the sleeve portion, and a centering collar. The disk portion includes a first end face and the centering collar is formed on the first end face. The freewheel unit includes an outer ring fastened to the sleeve portion by press fitting, and a plurality of rolling elements accommodated within the outer ring. The outer ring includes a plurality of clamping ramps, and each one of the plurality of rolling elements cooperates with a one of the plurality of clamping ramps.