Segmented Laminated Inner Race Assembly for Multi-Mode Clutch Manufacturing
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Solution Overview
Problem
Current multi-mode clutch manufacturing methods are costly due to the use of various materials and require secondary processing steps to achieve specified thicknesses, leading to inefficiencies in material usage and production processes.
Innovation Solution
A segmented and laminated rotatable inner race design for multi-mode clutch modules, comprising arcuate segments with complementary end geometries and race engagement notches, allowing for interlocking joints and alignment to form a race ring, which can be assembled to achieve the desired thickness with reduced material waste and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional construction methods (wrought-machined steel, powdered metal) are used for inner and outer races, then material strength and durability are achieved, but manufacturing cost increases and secondary processing steps are required
Solution Approach 1:
The inner race is divided into multiple arcuate segments that can be manufactured separately and then assembled together. Each segment can be produced using cost-effective processes like stamping or forming, avoiding the need for expensive wrought-machined steel or powdered metal processes. The segments are joined using interlocking features such as tangs and slots, creating a complete inner race assembly that maintains structural integrity while reducing manufacturing complexity and cost.
2Stability of the object's composition
If traditional construction methods are used, then structural integrity is achieved, but material waste increases due to secondary processing to achieve specified thickness
Solution Approach 1:
The arcuate segments are pre-formed with the correct thickness and geometric features (such as engagement notches, oil holes, and surface contours) during the primary stamping or forming process. This eliminates the need for secondary machining or grinding operations that would otherwise remove material to achieve the specified thickness and features. The segments are designed with precise dimensions from the outset, ensuring structural integrity while minimizing material waste.
3Ease of manufacture
If segmented arcuate segments with interlocking joints are used, then manufacturing cost and complexity are reduced, but assembly precision and structural integrity must be maintained
Solution Approach 1:
The arcuate segments incorporate asymmetric interlocking features such as tangs, slots, and complementary geometries at their ends. These asymmetric features provide self-aligning and self-centering capabilities during assembly, ensuring that segments join together with high precision without requiring complex alignment procedures. The asymmetric design creates a unique fit between segments, preventing misalignment and ensuring consistent structural integrity across all assembled races.
4Manufacturing precision
If multiple secondary processing steps are used to achieve specified thickness, then manufacturing precision is achieved, but production time and cost increase
Solution Approach 1:
The arcuate segments are stamped or formed with the final specified thickness and all required features (engagement notches, oil holes, reinforcement ribs, etc.) in a single primary processing step. This eliminates multiple secondary machining and grinding operations that would otherwise be required to achieve the same precision. The segments are delivered ready-to-assemble with precise dimensions, significantly improving production efficiency while maintaining the required thickness precision for proper fit and function.
Data Source
AI summary
A rotatable inner race is disclosed. The inner race may include a plurality of arcuate segments each having a first end with a first end geometry and a second end with a second end geometry. The first and second end geometries may be complimentary to each other to join adjacent arcuate segments at an interlocking joint. The rotatable inner race may further include a plurality of race engagement notches extending radially from an outer circumferential surface of each arcuate segment and the plurality of arcuate segments are joined together at the interlocking joints to form a race ring and the plurality of race engagement notches of each arcuate segment align with one another to define an array of race engagement notches around an outer circumference of the race ring.