Segmented Steel Core Plates for Wet Clutch Friction Discs
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Solution Overview
Problem
The manufacturing process of steel core plates for wet clutch applications results in significant material waste due to multi-step processes and inefficient blanking out of core plates, which existing methods have not adequately addressed.
Innovation Solution
The development of segmented steel core plates with interlocking end portions, where the number of spline teeth is either divisible by 3 (prime segments) or not evenly divisible by 3 or 5 (non-prime segments), allowing for improved manufacturing efficiency by reducing scrap material through optimized segmenting and lamination processes, including the use of cam-activated assemblies and perforations for alignment and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional blanking processes are used to manufacture core plates, then manufacturing simplicity is maintained, but material waste is significant
Solution Approach 1:
The core plate is divided into multiple segments that can be manufactured separately and then assembled together. This segmentation allows each segment to be optimized for efficient blanking while the overall structure achieves reduced material waste through the assembly process. The segments are designed with interlocking features that facilitate precise alignment and bonding.
Solution Approach 2:
Multiple core plate segments are combined through bonding to form the complete core plate structure. This merging process allows the assembly to achieve better material utilization than conventional single-piece blanking, as the segments can be arranged and bonded to minimize scrap material while maintaining structural integrity.
2Manufacturing precision
If multi-step manufacturing processes are used, then manufacturing precision can be improved, but productivity decreases
Solution Approach 1:
The segments are pre-manufactured with precise dimensions and interlocking features before final assembly. This preliminary action allows each segment to be optimized for precision manufacturing while the modular nature enables parallel production, ultimately improving overall productivity despite the multi-step process.
Solution Approach 2:
By segmenting the core plate, the manufacturing process can be divided into independent segment production and assembly phases. This allows for specialized precision manufacturing of each segment while enabling concurrent production of multiple segments, thereby maintaining high precision without proportionally reducing productivity.
3Strength
If core plates are segmented with interlocking portions, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The core plate is segmented into multiple sections with interlocking portions that provide structural connection. These interlocking features are designed to be simple in form but effective in function, creating strong joints between segments while avoiding overly complex structural designs. The segmentation allows for stress distribution across multiple connection points.
Solution Approach 2:
The segmented core plate structure combines multiple segments with interlocking portions and bonding interfaces to create a composite structure. This composite approach enhances overall structural integrity by distributing loads across multiple components and connection points, while the design of the interlocking portions keeps the added complexity manageable.
Data Source
AI summary
Segmented steel core plates for either double sided or single sided wet clutch friction plates or separator plates and a process for making the same are disclosed.