Stepped-Groove Collar and Shaft Assembly for High-Force Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current metal forming dies are labor-intensive and costly to design, manufacture, and modify due to the need for custom-designed and precision-machined components, with existing collar and shaft assemblies being prone to breaking or shearing under large forces and requiring complex assembly processes.
Innovation Solution
A collar and shaft assembly featuring a cylindrical shaft with a stepped groove and a collar with a tapered inner sidewall, combined with a retainer ring that is securely seated in the groove, allowing for easy assembly and high-force resistance without breaking or shearing, using a method where the collar is advanced over the shaft to compress and seat the retainer ring, creating a permanent and tamper-proof connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional custom-designed and precision-machined components are used in metal forming dies, then the strength and reliability of the assembly is improved, but the manufacturing complexity and cost increase substantially
Solution Approach 1:
The collar is divided into two functional portions: a cylindrical outer surface for mounting onto the shaft, and a tapered inner surface for receiving the retainer ring. This segmentation allows each portion to be optimized independently - the outer surface for simple cylindrical machining and the tapered surface for secure retainer ring engagement - thereby reducing overall manufacturing complexity while maintaining strength
Solution Approach 2:
The retainer ring is nested within the tapered bore of the collar, creating a compact assembly where the retainer ring sits inside the collar's internal tapered cavity. This nesting arrangement eliminates the need for separate external retention mechanisms and reduces the number of discrete components required, simplifying the overall device structure
2Reliability
If traditional custom-designed components with precision-machined mounting features are used, then the reliability of the assembly is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The collar's tapered bore is segmented into a cylindrical outer surface (easy to machine with standard turning operations) and a tapered inner surface (providing secure retainer ring engagement). This segmentation allows the majority of the collar to be manufactured using simple, high-volume cylindrical machining processes, while only a portion requires the more complex tapered geometry, thereby improving ease of manufacture while maintaining reliability
Solution Approach 2:
The tapered bore of the collar serves multiple functions: it provides the mounting interface for the retainer ring, defines the internal geometry for force distribution, and creates the retention mechanism itself through the interaction between the tapered surface and the retainer ring. This multi-functionality eliminates the need for separate retention features, simplifying manufacturing while ensuring reliable assembly
3Ease of manufacture
If a simple cylindrical collar design is used, then the ease of manufacture is improved, but the ability to resist large forces without breaking or shearing deteriorates
Solution Approach 1:
The collar exhibits local quality variations: the outer surface maintains a simple cylindrical geometry for ease of manufacture, while the inner surface features a tapered portion specifically at the region where force transmission occurs. This localized tapering provides enhanced force resistance and secure retainer ring engagement exactly where needed, without complicating the overall manufacturing process
4Reliability
If a permanent connection method is used to prevent collar removal, then the reliability is improved, but the ease of assembly deteriorates
Solution Approach 1:
The tapered geometry of the collar's inner surface automatically performs the retention function during the assembly process itself. As the collar is mounted onto the shaft, the tapered surface naturally guides and secures the retainer ring into place without requiring separate fastening operations. The same tapered geometry that provides force resistance also creates the permanent connection, eliminating the need for additional assembly steps while ensuring reliable, tamper-proof attachment
Data Source
AI summary
A collar and shaft assembly utilizing a ring and a multi-stepped groove. The multi-stepped groove permits the ring to be compressed into one groove while the collar is being assembled and then to expand into a different groove that permits the ring to contact surfaces on both the collar and the shaft.