Segmented Washer Assembly for Higher Material Yield
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Solution Overview
Problem
Conventional washer manufacturing methods result in poor material yield due to significant space between adjacent washers, leading to wastage of material.
Innovation Solution
A washer design featuring interlocking circular arc-shaped members with protruding and recessed fitting portions, where the fitting portions are crimped to form a crimped portion and an oil reservoir, allowing for improved material utilization and firm fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If washers are manufactured by punching plate-shaped material with a mold, then washers can be produced efficiently, but significant space between adjacent washers causes poor material yield
Solution Approach 1:
The washer is divided into multiple independent arc-shaped members (first member, second member, third member, fourth member) that can be arranged closely together. Each member is a separate component that can be manufactured independently and then assembled, eliminating the need for large spacing required in traditional punching methods while maintaining manufacturing efficiency.
Solution Approach 2:
The arc-shaped members are fitted together in a nested arrangement where each member interlocks with its neighbors through protruding and recessed fitting portions. This nesting allows maximum density of material utilization with minimal waste space between components, significantly improving material yield compared to traditional punching methods.
2Loss of substance
If arc-shaped members are fitted together with protruding and recessed fitting portions, then material yield improves, but the members require firm fixation to maintain structural integrity
Solution Approach 1:
The fitting portions are designed with predetermined protruding and recessed geometries that guide the assembly process. The protruding portions of one member are designed to fit into the recessed portions of adjacent members before final fixation, ensuring proper alignment and preliminary structural stability before the fitting is completed.
Solution Approach 2:
The fitting portions utilize curved and rounded geometries rather than sharp angles. The protruding and recessed portions have smooth transitions that distribute stress evenly across the joint, enhancing the strength and durability of the connection between arc-shaped members while maintaining structural integrity.
3Loss of substance
If multiple arc-shaped members are assembled with fitting portions, then material utilization improves, but the assembly process becomes more complex
Solution Approach 1:
The fitting portions are designed with asymmetric protruding and recessed geometries that provide directional guidance during assembly. This asymmetry ensures that members can only be assembled in the correct orientation, simplifying the assembly process by eliminating the need for complex alignment procedures while maximizing material utilization.
Solution Approach 2:
The interface between fitting portions is designed to be substantially flat when mated, creating an equipotential surface that simplifies the assembly process. This flat mating surface ensures uniform contact and stress distribution, reducing assembly complexity while maintaining high material utilization efficiency.
Data Source
AI summary
A washer includes a first washer piece formed in a circular arc shape and formed with a first fitting portion that protrudes from one end in a circular arc direction; and a fourth washer piece formed with a second fitting portion that is recessed from one end in the circular arc direction and fitted with the first fitting portion. The first fitting portion and the second fitting portion are fitted in a state where approach and separation therebetween in the circular arc direction is controlled. One of the first fitting portion and the second fitting portion includes a crimped portion that is formed in a state where a side surface of the one of the fitting portions is pushed into a side surface of the other of the fitting portions, the one of the fitting portions being fixed to the other of the fitting portions by the crimped portion.