Integrated Torque Limiter Assembly for Low-Cost Friction Clamping
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Solution Overview
Problem
Existing torque limiters in motor vehicle transmission systems are costly and difficult to assemble due to the use of multiple parts and complex riveting processes, which increases manufacturing and assembly costs and complexity.
Innovation Solution
A torque limiter design featuring an integrally formed first ring and second ring with a spring washer that clamps a friction disc, eliminating the need for riveting and simplifying assembly, while allowing for adjustable torque limitation through support teeth and anti-rotation features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two cover plates are used to clamp the friction disc, then the clamping function is achieved, but the manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The patent merges two separate cover plates into a single integrated cover structure. The single cover includes a first clamping surface and a second clamping surface formed on different portions of the same component, eliminating the need for riveting two plates together. This reduces the number of parts, simplifies assembly, and lowers manufacturing cost while maintaining the clamping function.
Solution Approach 2:
The single cover plate performs multiple functions: it provides both the first clamping surface and the second clamping surface, supports the elastic component, and serves as the torque limiter cover body. This multi-functional design eliminates the need for separate components and reduces overall device complexity.
2Reliability
If two cover plates riveted together are used, then the clamping function is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent combines two separate cover plates into one integrated single cover component. This eliminates the riveting process and reduces the number of parts that need to be manufactured, stored, and assembled. The single cover can be manufactured as one piece, reducing material costs, manufacturing complexity, and overall production cost while maintaining the necessary clamping function.
3Stability of the object's composition
If a large number of rivets are used to connect cover plates, then the connection tightness is improved, but the assembly process becomes complicated and quality control becomes difficult
Solution Approach 1:
The patent eliminates the need for rivets by merging two cover plates into a single integrated cover. The single cover is manufactured as one piece with integrated clamping surfaces, completely removing the riveting process from the assembly. This eliminates assembly complexity, eliminates the risk of rivet loss, and removes the need for quality control of riveting processes while maintaining structural integrity.
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
The design reduces manufacturing and assembly costs, simplifies the assembly process, and effectively limits torque fluctuations by sliding the friction disc when maximum torque is exceeded, thereby reducing noise and vibration.
Implementation Method 1
a spring washer (5) axially arranged between the first ring (1) and the pressure ring (3), wherein the pressure ring (3) receives a pressing force from the spring washer (5)
Implementation Method 2
when the torque transmitted from the flywheel to the torque limiter reaches or exceeds the maximum torque of the torque limiter, the friction disc is slidable between the second ring and the pressure ring, thereby limiting the torque output by the torque limiter to the maximum torque
Data Source
AI summary
A torque limiter includes a first ring adapted to be fixed to a flywheel and being driven to rotate about a rotation axis, a second ring a certain distance from the first ring, and a compression ring between the first ring and the second ring. A friction disc is slidably sandwiched between the second ring and pressure ring, and a spring washer is arranged between the first ring and pressure ring, the pressure ring receiving a pressing force from the spring washer and pressing the friction disc against the second ring. The first and second ring are integrally formed, the first ring provided with first teeth, the spring washer provided with support teeth, and each support tooth is supported by one first tooth. A transmission system includes the above-described torque limiter.