Freewheeling Cage Coupling Disk for Rigid Easy Assembly
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Solution Overview
Problem
Existing freewheeling mechanisms are complex to manufacture and lack sufficient structural rigidity, which affects their ease of assembly and stability.
Innovation Solution
A freewheeling mechanism design featuring a sheet metal cage with a coupling disk and coupling structure that allows for easy assembly and increased structural rigidity, utilizing a coupling rim with a double material thickness and a non-rotationally symmetric coupling structure that interlocks with the freewheeling member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a coupling disk with double material thickness is used to enhance structural rigidity, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The coupling disk integrates the support portion and coupling structure into a single monolithic component with double material thickness at the coupling rim. This merging of functions into one piece enhances structural rigidity while simplifying manufacturing by eliminating the need to assemble multiple separate parts.
Solution Approach 2:
The coupling structure extends in the axial dimension by incorporating a coupling disk that adjoins the support portion axially. This adds thickness in the axial direction to create double material thickness at the coupling rim, enhancing structural rigidity without increasing radial or circumferential dimensions.
2Reliability
If a non-rotationally symmetric coupling structure is used to prevent accidental disengagement, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The coupling structure features a non-rotationally symmetric design where the coupling portion has a specific profile that matches the clamping structure. This asymmetric geometry prevents accidental disengagement by ensuring the coupling can only engage in one orientation, thereby improving reliability while maintaining manufacturability through standard forming processes.
3Ease of manufacture
If the support portion and coupling disk have the same external diameter to simplify assembly, then ease of manufacture is improved, but structural rigidity may be compromised
Solution Approach 1:
The coupling disk has the same external diameter as the support portion, creating a uniform outer轮廓 that simplifies assembly. However, the double material thickness is achieved locally at the coupling rim where the coupling disk adjoins the support portion axially, providing enhanced structural rigidity precisely where needed for the coupling function.
Data Source
AI summary
A freewheeling mechanism includes a freewheeling member with a clamping structure, clamping parts arranged on the clamping structure, and a sheet metal cage for spacing the clamping parts in a direction of revolution. The sheet metal cage is placed on the freewheeling member and includes a base body with a support portion extending radially outward and a coupling rim on a first axial side. The coupling rim includes a coupling disk fixed coaxially on the base body and adjoining the support portion. The coupling disk includes a coupling portion with a coupling structure for interlocking coupling to the clamping structure such that the sheet metal cage is held on the freewheeling member for conjoint rotation. The support portion and the coupling disk have a same external diameter with assembly recesses provided at their respective outer circumferences, and the assembly recesses lie over one another in an assembled state.