Segmented Pressure Plate Assembly for Large Clutch Manufacturing
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Solution Overview
Problem
Existing pressure plate assemblies for clutch devices face limitations in manufacturing due to required deformation and are only designed for clutch sizes up to 200 mm, restricting sheet thickness and functionality.
Innovation Solution
A pressure plate assembly with a base plate and cam ring connected via leaf spring tab sections, allowing the base plate thickness to remain constant while varying the cam ring height, enabling larger clutch sizes and secure torque transmission through leaf spring rivets and a disk spring force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pressure plates are produced with large degrees of deformation to accommodate larger clutch sizes, then clutch size capability is improved, but manufacturing complexity and sheet thickness limitations worsen
Solution Approach 1:
The pressure plate is divided into two separate components: a base plate and a cam ring. The base plate maintains a constant, manufacturable thickness (6-9mm) while the cam ring provides the necessary height variation. This segmentation allows each component to be manufactured independently with standard thicknesses, avoiding the need for large deformations of thick plates while still achieving the required functionality for larger clutch sizes.
2Strength
If sheet thickness is increased to handle larger clutch sizes, then force absorption capability is improved, but manufacturing limitations and deformation requirements worsen
Solution Approach 1:
The force absorption function is separated between the base plate (which handles thickness-related strength) and the cam ring (which handles height-related functionality). The base plate can be manufactured with optimal constant thickness (6-9mm) for strength without requiring large deformations, while the cam ring is formed with varying height through pressing or drawing processes to provide the necessary mechanical function for larger clutch sizes.
3Stability of the object's composition
If pressure plates are designed as single-piece structures, then structural integrity is improved, but adaptability to different clutch sizes and height requirements worsens
Solution Approach 1:
The pressure plate is segmented into a base plate and cam ring that are firmly connected via leaf spring tab sections. This segmentation allows the base plate to maintain constant thickness for structural stability while the cam ring provides variable height for adaptability to different clutch sizes. The firm connection through leaf spring tabs ensures the segmented structure functions as a unified component with maintained structural integrity.
4Adaptability or versatility
If base plate thickness is varied to accommodate different clutch sizes, then clutch size adaptability is improved, but manufacturing consistency and force absorption predictability worsen
Solution Approach 1:
The base plate is designed with constant thickness (6-9mm) to ensure manufacturing consistency and predictable force absorption characteristics. The adaptability to different clutch sizes is achieved through the cam ring, which has variable height formed through pressing or drawing processes. This segmentation allows the base plate thickness to remain consistent across different clutch size applications while still achieving the necessary adaptability through the cam ring geometry.
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
Enables the production of pressure plates for larger clutch sizes with consistent base plate thickness, enhanced force absorption, and secure torque transmission without additional components, overcoming manufacturing and size limitations of prior art.
Implementation Method 1
the base plate and the cam ring being connectable to one another via the leaf spring tab sections
Implementation Method 2
a disk spring force generated by the lever element
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a pressure plate assembly 1 with at least one clutch cover 2, at least one pressure plate 3 arranged at least partially within the clutch cover 2, which is rotationally fixed to it by leaf springs 9 and is axially displaceable within limits in the axial direction 16 of the pressure plate assembly 1 for frictionally clamping a clutch disc between the pressure plate 3 and a counter-pressure plate, and at least one lever element 6 which is tiltably mounted on the clutch cover 2 by means of a pivot bearing, wherein the pressure plate 3 has a base plate 4 with first leaf spring tab sections 10 and a cam ring 5 with second leaf spring tab sections 11, wherein at least one of the leaf springs 9 is rigidly connected to at least one of the first leaf spring tab sections 10 and at least one of the second leaf spring tab sections 11 of the pressure plate 3.