Friction Lamella Segment Offset for Compressibility Control
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Solution Overview
Problem
The compressibility of composite friction linings in all-wheel drive systems varies significantly due to material inconsistencies, making it challenging to maintain within narrow tolerances, which affects the performance and reliability of torque distribution in lamellar clutches.
Innovation Solution
The method involves offsetting the segments of one friction lining by a defined angle relative to the other, using a rotation unit or offsetting projections on stamps to produce grooves, allowing for precise control of compressibility within a pre-definable tolerance range, thereby equalizing variations in raw material properties and reducing production testing effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite friction linings are used in lamellar clutches, then the coefficient of friction consistency and level are improved, but the compressibility increases and varies significantly
Solution Approach 1:
The invention changes the geometric parameters of the friction lining by introducing grooves that divide it into segments. These segments are offset by a defined angle (α) between 0.1° and 8° relative to corresponding segments on opposing friction linings. This parameter change compensates for material variations and reduces compressibility variation to within a tolerance range of 0.15% to 2.5%, resolving the contradiction between using composite materials and maintaining manufacturing precision.
2Manufacturing precision
If the segments of friction linings are offset by a defined offset angle, then the compressibility variation is reduced to within a pre-definable tolerance range, but the device complexity increases due to additional production equipment
Solution Approach 1:
The invention implements preliminary action by pre-defining the offset angle (α) during the groove production stage. The grooves are created with specific angular offsets using stamping tools or laser technology before the friction linings are assembled into the clutch. This preliminary configuration ensures that compressibility remains within tolerance ranges without requiring complex real-time adjustment mechanisms, thus resolving the contradiction between manufacturing precision and device complexity.
3Manufacturing precision
If increased production testing is performed to check compressibility, then the compressibility tolerance can be verified, but the productivity decreases and production costs increase
Solution Approach 1:
The invention implements self-service by designing the friction lining geometry (segmented grooves with offset angle α) to inherently compensate for material variations. This self-compensating design ensures that compressibility automatically remains within acceptable tolerance ranges (0.15% to 2.5%) without requiring extensive external testing or quality control interventions. The structure itself performs the quality assurance function, resolving the contradiction between manufacturing precision verification and productivity.
Data Source
AI summary
The invention relates to a friction lamella (1) comprising a disk-shaped carrier element (2) having a first surface (3) and a second surface (4) opposite thereto, a first friction lining (5) being situated on the first surface (3) and a second friction lining (6) being situated on the second surface (4), which are formed from a composite material, comprising a resin and a fibrous material, and grooves (9, 10) being situated in the first and in the second friction linings (5, 6), which divide the friction linings (5, 6) into segments (7, 8) at least in surface-proximal areas. The segments (7) of the first friction lining (5) are implemented offset by a defined offset angle (11) to the segments (8) of the second friction lining (6). Furthermore, the invention relates to a method and a device for producing the friction lamella and the use of the friction lamella.