Integrated Clutch Basket Geometry for Lighter Transmission Packaging
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Solution Overview
Problem
Conventional clutch systems for transmissions lack improvements in design, particularly in terms of weight reduction, size optimization, and bearing count, which are crucial for applications like aircraft engines where space and weight are critical.
Innovation Solution
The design of a clutch basket with a clutch housing and integral or mounted gears, where the housing and gear diameters are distinct, allowing the clutch housing to extend radially past the gears, and featuring a second neck portion with a smaller diameter and additional gears, enabling a more compact and lightweight configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional clutch designs are used, then the clutch system is structurally simple, but the weight and size are excessive for aircraft applications
Solution Approach 1:
The patent merges the clutch housing with gear structures by integrally forming gears directly on the clutch housing. This integration eliminates the need for separate gear components and their associated bearings, thereby reducing overall weight and component count while maintaining structural integrity and functionality.
Solution Approach 2:
The clutch housing is designed to serve multiple functions simultaneously: it houses the clutch pack, provides structural support, and incorporates gear elements directly onto it. This multi-functionality reduces the number of separate components needed, leading to weight reduction and simplified assembly while preserving all necessary mechanical functions.
2Volume of moving object
If conventional clutch designs with co-axial shafts are used, then the power transmission path is simple, but the size and bearing requirements are increased
Solution Approach 1:
The patent transitions from a traditional co-axial power transmission arrangement to a design where power is transmitted through gears mounted on the clutch housing itself. This dimensional reorganization allows power flow to occur through the housing structure rather than requiring separate co-axial shafts, thereby reducing the overall envelope size while maintaining effective power transmission.
3Weight of stationary object
If traditional clutch housing designs are used, then manufacturing is straightforward, but weight and component count are reduced
Solution Approach 1:
The clutch housing is integrally formed with gear structures, combining what would traditionally be separate manufactured components into a single monolithic structure. This integration eliminates the need for separate gear manufacturing, assembly operations, and multiple bearings, thereby reducing weight and component count despite requiring more advanced manufacturing capabilities.
Data Source
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AI summary
A clutch basket (100) of a clutch (199) for a transmission can include a clutch housing (101) shaped to house a clutch pack (103) in the clutch housing (101), wherein the clutch housing (101) has a housing outer diameter (101a), a neck (105) integral with and extending axially from the clutch housing (101), the neck (105) having a neck outer diameter (105a) smaller than the housing outer diameter (101a), at least a first gear (107) integrally formed or mounted on the neck (105) and extending radially outward from the neck (105), wherein the first gear (107) includes a first gear outer diameter (107a). In certain embodiments, the housing outer diameter (101a) can be different from the first gear outer diameter (107a).