Hybrid Washer Wedge Structure for Vibration-Resistant Locking
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Solution Overview
Problem
Conventional washers lack effective engagement capabilities for locking purposes due to their flat surfaces, leading to issues like material inefficiency, sharp edges, and excessive wear in locking washers, necessitating a hybrid solution that combines the benefits of both conventional and locking washers.
Innovation Solution
A hybrid washer design featuring an inner ring with flat surfaces and an outer ring with a contoured engagement surface having radially extending wedges, allowing for frictional engagement with locking washers, made through conventional methods or powder metallurgy, which can function as both a conventional and locking washer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional washers with flat surfaces are used, then manufacturing is simple, but locking engagement capability is insufficient
Solution Approach 1:
The washer is divided into two distinct rings: an inner ring with a flat surface for bearing and distribution functions, and an outer ring with a contoured locking surface for engagement. This segmentation allows each ring to be optimized for its specific function while maintaining manufacturing simplicity through conventional forming processes.
Solution Approach 2:
Different regions of the washer are given different surface characteristics: the inner ring has a flat surface suitable for bearing loads, while the outer ring has a contoured surface with varying angles optimized for locking engagement. This local differentiation resolves the contradiction by providing appropriate surface qualities in specific locations without complicating overall manufacturing.
2Reliability
If locking washers with contoured surfaces are used, then locking capability is improved, but wear increases excessively
Solution Approach 1:
By separating the bearing function (inner ring with flat surface) from the locking function (outer ring with contoured surface), the design reduces wear on the locking surface. The flat inner ring distributes loads evenly, preventing excessive stress concentration that would accelerate wear on the locking engagement surfaces.
Solution Approach 2:
The contoured locking surface uses specifically optimized angle parameters (e.g., 45-degree angles) that balance locking effectiveness with wear reduction. These parameter optimizations allow the locking surface to engage effectively while minimizing friction and wear during operation.
3Productivity
If conventional fabrication processes are used, then production is efficient, but material waste is high
Solution Approach 1:
The inner ring and outer ring are formed as a single integrated washer component through conventional forming processes, eliminating the need for separate manufacturing and assembly steps. This merging maintains production efficiency while reducing material waste compared to using separate conventional washers and locking elements.
Solution Approach 2:
The hybrid washer combines multiple functions (bearing, distribution, and locking) into a single component, eliminating the need for separate washers and locking elements. This multi-functionality reduces the total material required while maintaining production efficiency through conventional forming processes.
4Reliability
If separate conventional and locking washers are used, then functionality is comprehensive, but device complexity increases
Solution Approach 1:
The patent merges the functions of a conventional washer and a locking washer into a single hybrid washer component. The inner ring provides conventional washer functions (bearing and load distribution), while the outer ring provides locking engagement, eliminating the need for multiple separate components and reducing assembly complexity.
Solution Approach 2:
The hybrid washer is designed as a universal component that performs multiple functions: it acts as a conventional washer for load bearing and distribution, while simultaneously providing locking engagement capabilities through its contoured outer ring. This multi-functionality reduces device complexity by consolidating what would otherwise require separate 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
The hybrid washer provides enhanced locking capabilities, reduces material waste, and adapts well to high vibration environments, eliminating the need for separate washers and enabling efficient production using recycled metal powders.
Implementation Method 1
The wedges form a plurality of crests contoured to frictionally engage a mating surface from a locking washer to fix the locking washer against the hybrid washer
Data Source
AI summary
A hybrid washer has an essentially disk-shaped body having an outer ring, an inner ring, and a bore extending through the inner ring. The outer ring has an engagement surface having a plurality of wedges with each wedge having a raised edge that extends radially and perpendicularly from a longitudinal axis projecting through the bore. The inner ring has a pair of spaced-apart essentially flat surfaces in overlying relation with one another. The wedges form a plurality of crests contoured to frictionally engage a mating surface from a locking washer to fix the locking washer against the hybrid washer.