Split Tolerance Ring Structure for Precise Torque Limiting
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Solution Overview
Problem
Existing tolerance rings face challenges in accommodating tight torque ranges between inner and outer members, requiring improved designs for precise torque transmission and overload protection in assemblies.
Innovation Solution
The tolerance ring design features a split ring with buckled regions and wave structure regions, which form an interference fit with the inner and outer members, allowing for precise torque transmission and overload protection by adjusting stiffness and contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a tolerance ring uses a simple band structure with stamped projections, then it can accommodate variations in diameter between inner and outer members, but it cannot provide precise torque transmission within tight torque ranges
Solution Approach 1:
The tolerance ring is divided into multiple regions with different stiffness characteristics: a first region with higher stiffness and a second region with lower stiffness. This segmentation allows different portions of the ring to perform different functions - the stiffer region provides precise torque transmission while the more compliant region accommodates dimensional variations and provides overload protection.
Solution Approach 2:
Different regions of the tolerance ring are designed with different local properties. The first region has increased stiffness (through greater thickness or denser material) to ensure precise torque transmission, while the second region has reduced stiffness to provide compliance and accommodate tolerances. This local differentiation resolves the contradiction between precision and adaptability.
2Reliability
If a tolerance ring is designed for overload protection within very precise predetermined torque values, then it can protect assemblies from damage, but it requires tight torque ranges that are difficult to achieve with conventional designs
Solution Approach 1:
The tolerance ring transitions from a static, uniform structure to a dynamic structure with regions of varying stiffness. Under normal operating conditions, the more compliant second region deforms to accommodate dimensional variations, while the stiffer first region maintains precise torque transmission. Under overload conditions, the design ensures predictable failure at predetermined torque values, providing reliable protection without requiring extremely tight manufacturing tolerances.
3Ease of manufacture
If a tolerance ring uses uniform thickness throughout, then it is easier to manufacture, but it cannot provide both precise torque transmission and accommodation of dimensional variations
Solution Approach 1:
Rather than using uniform thickness throughout the entire ring, the design applies local quality variations where only specific regions have different thicknesses. The first region has greater thickness for stiffness and precision, while the second region has reduced thickness for compliance. This localized differentiation maintains relative manufacturing simplicity while achieving the desired performance characteristics.
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 design effectively spans radial gaps with consistent torque transmission and overload protection, maintaining assembly integrity across varying conditions.
Implementation Method 1
The tolerance ring design features a split ring with buckled regions and wave structure regions, which form an interference fit with the inner and outer members, allowing for precise torque transmission and overload protection by adjusting stiffness and contact points.
Data Source
AI summary
An assembly including an outer member; an inner member; and a tolerance ring disposed between the inner member and the outer member, wherein the tolerance ring is a split ring comprising opposing edges, where the edges engaged with at one of the inner member or the outer member so as to prevent or restrict movement between the tolerance ring and at least one of the inner member or the outer member, or where the tolerance ring is deformed as installed between the inner member and the outer member and forms at least one buckled region in the tolerance ring due to an interference fit between the inner member and the outer member, where in an uninstalled state, the buckled region is absent.