Integrated Torque Limiter Structure for Rivet-Free Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing torque limiters in motor vehicle transmission systems are costly due to the use of multiple parts, particularly cover plates that require riveting, complicating assembly and increasing manufacturing and assembly difficulties.
Innovation Solution
A torque limiter design featuring integrally formed first and second rings with a spring washer supported by teeth, eliminating the need for riveting and simplifying assembly, while maintaining a compact and firm structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two cover plates are used to clamp the friction disc, then the friction disc can be effectively clamped, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent combines two separate cover plates into a single integrated cover plate structure. The integrated cover plate includes a first clamping surface and a second clamping surface that face each other, allowing the friction disc to be clamped between these surfaces without requiring multiple separate cover plates. This merging reduces the number of parts while maintaining the clamping function.
Solution Approach 2:
The integrated cover plate performs multiple functions: it provides both the first clamping surface and the second clamping surface, supports the elastic component, and maintains the structural integrity of the torque limiter. This multi-functional design eliminates the need for separate cover plates while achieving the same clamping effect.
2Strength
If two cover plates are riveted together, then the structure is firm, but the assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent integrates the functions of two cover plates into a single monolithic cover plate structure. This eliminates the need for riveting or other joining processes between multiple cover plates, simplifying manufacturing while maintaining structural firmness through the integrated design.
Solution Approach 2:
The patent extracts the riveting process and the second cover plate from the design, retaining only the essential clamping function through the integrated cover plate with its first and second clamping surfaces. This removal of unnecessary components and processes simplifies manufacturing.
3Manufacturing precision
If a large number of rivets are used to connect cover plates, then the connection is tight and uniform, but the assembly process is complicated and control costs increase
Solution Approach 1:
The patent merges the multiple riveted cover plates into a single integrated cover plate structure. This eliminates the need for multiple rivets and the complex riveting process, while maintaining connection uniformity through the monolithic design of the integrated cover plate.
4Reliability
If cover plates are riveted together, then the torque limiter structure is complete, but manufacturing cost and assembly difficulty increase
Solution Approach 1:
The patent combines multiple riveted cover plates into a single integrated cover plate that maintains structural completeness. The integrated design includes all necessary clamping surfaces and support features, eliminating the need for riveting while preserving the structural integrity and completeness of the torque limiter.
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
Reduces manufacturing and assembly costs by simplifying the structure and eliminating riveting steps, while effectively limiting torque fluctuations.
Implementation Method 1
a spring washer (5) axially arranged between the first ring and the pressure ring, the pressure ring receiving a pressing force from the spring washer and pressing the friction disc against the second ring
Implementation Method 2
when a torque fluctuation exceeds the maximum allowable torque, the torque limiter slides, thereby limiting the transmitted torque
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4
AI summary
The present disclosure relates to a torque limiter, comprising: a first ring adapted to be fixed to a flywheel, the first ring being driven to rotate about a rotation axis; a second ring that is at a certain distance from the first ring in the axial direction; a compression ring located between the first ring and the second ring in the axial direction; a friction disc slidably sandwiched between the second ring and the pressure ring; and a spring washer arranged axially between the first ring and the pressure ring, the pressure ring receiving a pressing force from the spring washer and pressing the friction disc against the second ring. The first ring and the second ring are integrally formed, the first ring is provided with a plurality of first teeth, the spring washer is provided with a plurality of support teeth, and each support tooth is supported by one first tooth. The present disclosure further relates to a transmission system comprising the above-described torque limiter and a method for assembling the above-described torque limiter.