Offset Clutch Disc Structure for Grind-Free Gear Wheel Units
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Solution Overview
Problem
Existing gear wheel units for manual transmissions are complex and costly to manufacture, with clutch discs requiring precise grinding on functional surfaces, which is inefficient and expensive, especially for mass production.
Innovation Solution
A gear wheel unit design where the radially inner and outer clutch disc sections have equal thickness, with sections offset along the central axis, allowing for forming processes to create precise contact surfaces, reducing material usage and enabling cost-effective, lightweight production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If clutch discs are ground on both sides to maintain necessary tolerances on functional surfaces, then manufacturing precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The clutch disc blank is pre-formed with the correct thickness and contact surface geometry before final assembly. The forming process creates the precise thickness variation and contact surfaces in advance, eliminating the need for subsequent grinding operations to achieve tolerances.
Solution Approach 2:
The invention changes the thickness parameter of the clutch disc blank from uniform to non-uniform, with the radially inner section having a different thickness than the radially outer section. This parameter change allows the contact surfaces to be formed directly during the forming process, achieving the required precision without grinding.
2Manufacturing precision
If clutch discs are ground to achieve tight tolerances, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The clutch disc blank is pre-formed with the correct thickness and contact surface geometry before final assembly. The forming process creates the precise thickness variation and contact surfaces in advance, eliminating the need for subsequent grinding operations to achieve tolerances.
Solution Approach 2:
The invention replaces the mechanical grinding process with a forming process. Instead of removing material through grinding to achieve tolerances, the correct geometry is formed directly during blank formation, significantly increasing production speed while maintaining precision.
3Strength
If a solid clutch disc is used, then structural strength is improved, but weight increases
Solution Approach 1:
The clutch disc is designed with non-uniform thickness, where the radially inner clutch disc section has a different thickness than the radially outer section. This local variation in quality allows material to be removed only where not needed for strength, reducing weight while maintaining structural integrity in critical areas.
Solution Approach 2:
The clutch disc is divided into two distinct sections: a radially inner clutch disc section and a radially outer clutch disc section. This segmentation allows each section to have optimized thickness for its specific functional requirements, reducing overall weight while maintaining necessary strength in each zone.
4Ease of manufacture
If traditional clutch disc blanks are used, then ease of manufacture is improved, but material usage increases
Solution Approach 1:
The clutch disc is designed with non-uniform thickness, where the radially inner clutch disc section has a different thickness than the radially outer section. This local variation in quality allows material to be removed only where not needed for strength, reducing weight while maintaining structural integrity in critical areas.
Solution Approach 2:
The invention changes the thickness parameter of the clutch disc blank from uniform to non-uniform, with the radially inner section having a different thickness than the radially outer section. This parameter change allows the contact surfaces to be formed directly during the forming process, achieving the required precision without grinding.
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 solution simplifies the gear wheel unit's structure and manufacturing process, allowing for quick and inexpensive production of clutch discs with tight tolerances, making it suitable for series production and reducing material usage, resulting in a lightweight and reliable gear wheel unit.
Implementation Method 1
the radially inner clutch disc section is formed in relation to the radially outer clutch disc section in the direction in which the central axis extends, and in this way a first contact surface is formed on the radially inner clutch disc section
Data Source
AI summary
A gear unit (10) for a synchronizer unit of a manual transmission is described. This unit comprises a gear (12) and a clutch disc (14) attached to the gear (12). The clutch disc (14) has a radially inner clutch disc section (22) and a radially outer clutch disc section (20). One of the two clutch disc sections (20, 22) is at least partially deformed relative to the other clutch disc section (20, 22) in the direction of a central axis (16). Furthermore, a method for manufacturing a clutch disc (14) for a gear unit (10) is presented.