Retainer Ring Installation Tool for Starter Drive Assemblies
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Solution Overview
Problem
The manual installation of retainer rings in starter drive assemblies is labor-intensive, prone to errors, and causes muscle fatigue due to the constant use of chisels and hammers, leading to process variations.
Innovation Solution
An insertion tool with a horizontal frame, a handle, and a pivotally attached installation element with a hook portion that applies a force parallel to the groove's central axis upon handle rotation, reducing the need for constant chisel and hammer use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion process is used with chisel and hammer, then flexibility and simplicity are maintained, but productivity is low and operator fatigue increases
Solution Approach 1:
The patent introduces a specialized insertion tool as an intermediary device between the operator and the retainer ring. The tool includes a handle for operator input, a transmission mechanism with gear and cam, and an insertion element that contacts the retainer ring. This intermediary mechanism converts manual rotational motion into linear insertion force, significantly reducing operator fatigue while increasing insertion speed and consistency.
2Manufacturing precision
If manual insertion process is used, then device complexity is low, but manufacturing precision and consistency are poor due to process variations
Solution Approach 1:
The patent employs dynamic elements including a rotatable handle, a gear mechanism for motion conversion, and a cam mechanism for force transmission. The cam profile is specifically designed to provide controlled insertion force throughout the rotation cycle. These dynamic components transform simple rotational input into precise linear insertion motion, ensuring consistent placement of the retainer ring while maintaining reasonable device complexity.
3Reliability
If constant use of chisel and hammer is required, then ease of manufacture of tool is high, but reliability decreases due to operator errors and fatigue
Solution Approach 1:
The patent replaces the direct manual mechanical action of hammering with a mechanical system that converts rotational motion into controlled linear insertion force. The gear-cam mechanism provides mechanical advantage and force multiplication, eliminating the need for repeated hammer strikes. This substitution improves reliability by ensuring consistent insertion force while the tool remains manufacturable using conventional machining processes.
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 tool efficiently and accurately installs retainer rings with reduced operator fatigue and error, simplifying the process while being cost-effective and easy to manufacture.
Implementation Method 1
the installation element is configured to apply an insertion force on the retainer ring upon rotation of the handle portion about a central axis of the groove to force the retainer ring into the groove. The insertion force acts in a direction generally parallel to the central axis of the groove.
Implementation Method 2
rotation of the handle portion about a central axis of the groove
Implementation Method 3
an installation element extending downwards from the horizontal frame member and pivotally attached thereto. The installation element is configured to engage within the retainer ring and apply an insertion force upon rotation of the handle portion
Data Source
AI summary
An insertion tool for installation of a retainer ring within a groove is provided. The insertion tool includes a generally horizontal frame member. The insertion tool also includes a handle portion extending upwards from the horizontal frame member. The insertion tool further includes an installation element extending downwards from the horizontal frame member and pivotally attached thereto. The installation element is configured to engage within the retainer ring. Further, the installation element is configured to apply an insertion force on the retainer ring upon rotation of the handle portion about a central axis of the groove to force the retainer ring into the groove. The insertion force acts in a direction generally parallel to the central axis of the groove.