Slip Clutch Spring Preload Assembly and Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power tool clutch mechanisms have high manufacturing and assembly costs due to the large number of separate elements, which complicates the construction and assembly process while providing a stable spring characteristic.
Innovation Solution
A common support element, such as a guide frame, is used to manage all spring elements independently of the tool housing, allowing for simple assembly and adjustment of the preload, with guide parts and an intermediate disc ensuring axial compression and preventing side deviations during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plurality of separate spring elements are used in the clutch mechanism, then the spring characteristic remains uniform and stable during service life, but the number of separate elements increases manufacturing and assembly costs
Solution Approach 1:
Multiple separate spring elements are merged into a single spring element with a multi-leaf structure. This spring element comprises multiple leaves (first leaf, second leaf, third leaf) that are connected to each other, forming an integrated component that replaces what would traditionally require multiple separate springs. This merging maintains the stable spring characteristic while reducing the number of separate elements to be manufactured and assembled.
Solution Approach 2:
The single spring element is segmented into multiple leaves connected in sequence. Each leaf can be seen as a segment of the overall spring structure, allowing the spring to function as multiple separate springs would while being manufactured as a single integrated piece. The segmentation is achieved through the connected leaf structure where each leaf contributes to the overall spring characteristic.
2Reliability
If multiple separate clutch elements and spring elements are used, then torque transmission can be reliably controlled, but assembly and manufacturing become more complex and costly
Solution Approach 1:
The clutch mechanism integrates multiple functions into fewer components. The single multi-leaf spring element combines the functions of multiple separate springs, and the clutch element is designed to work with this integrated spring structure. This merging reduces the total number of parts that need to be manufactured and assembled while maintaining reliable torque transmission control through the clutch's engagement and disengagement mechanism.
Solution Approach 2:
The single spring element with multiple leaves serves multiple functions simultaneously: it provides the spring force for clutch engagement, maintains the clutch elements in their engaged position, and allows for controlled disengagement. This multi-functional design reduces the need for multiple specialized components, simplifying both manufacturing and assembly processes while ensuring reliable torque transmission control.
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
This approach simplifies the assembly and adjustment of the preload, reduces manufacturing costs, and maintains a stable spring characteristic while preventing undesirable torque interruptions, enabling efficient torque transmission.
Implementation Method 1
a plurality of separate spring elements for preloading the clutch elements against the counter-clutch elements of the control element
Implementation Method 2
guide parts and an intermediate disc ensuring axial compression and preventing side deviations during rotation
Implementation Method 3
a slip clutch for transmitting torque from the drive to the output member
Data Source
AI summary
A power tool includes an output member (8) projecting from the tool housing (4), a drive (6) located in the housing for rotating the output member (8), and a slip clutch (22) for transmitting torque from the drive (6) to the output member (8) and including a plurality of clutch elements (24) retained against rotation relative to the housing (4), a plurality of separate spring elements (28) for adjustable preloading the clutch elements (24) against the counter-clutch elements (51) of the control element (18) for retaining the control element (18) against rotation upon application of the torque thereto until threshold of the torque is reached, and a common support element for supporting the spring elements and movable relative to the housing (4).