Torque Limiter Friction Member Fixation via Integrated Molding
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Solution Overview
Problem
Existing torque limiters face challenges in fixing friction members at a low cost and require axis-alignment operations for radial positioning, which increases complexity and cost.
Innovation Solution
A torque limiter design featuring a drive member with axially penetrating holes and friction members of greater thickness, fixed via press-fitting, and a damper mechanism with torsion springs for elastic coupling, eliminating the need for axis-alignment and reducing axial size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rivet swaging is used to fix friction members, then the friction members are securely fixed, but the friction (burn-off) length is reduced and additional processing steps are required
Solution Approach 1:
The friction member is integrated with the cushioning plate as a single unit, eliminating the need for separate fixation processes such as rivet swaging. This merging of components maintains secure fixation while reducing manufacturing complexity and preserving the friction length.
Solution Approach 2:
The cushioning plate is designed to serve multiple functions: it provides cushioning, positions the friction member, and integrates the friction member into a unified structure. This multi-functionality eliminates the need for dedicated fixation mechanisms.
2Ease of manufacture
If adhesive material is used to fix friction members, then the friction members are fixed without reducing friction length, but the number of processing steps increases and cost increases
Solution Approach 1:
The friction member and cushioning plate are merged into a single integrated component through molding or forming processes. This eliminates the need for adhesive materials and reduces the number of processing steps while preserving the full friction length.
Solution Approach 2:
The mechanical integration process (molding or forming) replaces the chemical bonding process (adhesive application). This substitution reduces processing steps and eliminates the need for additional materials while maintaining the friction member's full length.
3Reliability
If torque limiter is fixed to flywheel using bolts with axis-alignment, then secure fixation is achieved, but the attachment process becomes complex and time-consuming
Solution Approach 1:
The friction member is pre-integrated with the cushioning plate during manufacturing, creating a unified assembly. This preliminary action eliminates the need for time-consuming axis-alignment operations during installation, as the integrated structure self-aligns when mounted to the flywheel.
Solution Approach 2:
The friction member and cushioning plate are combined into a single assembly that attaches to the flywheel as one unit. This merging simplifies the attachment process by reducing the number of separate components that require alignment and fixation.
4Ease of manufacture
If integration by molding is used to fix friction members, then the fixation is strong and simple, but the available cushioning shapes are limited and cost is high
Solution Approach 1:
The cushioning plate can be manufactured using various processes (molding, forming, bending) that allow different shapes and configurations. By changing the manufacturing parameters and methods, a wide range of cushioning shapes can be achieved without compromising the integration of the friction member.
Solution Approach 2:
The cushioning plate is designed as a separate but integrated component that can be independently shaped and configured. This segmentation allows for greater design flexibility and variety in cushioning shapes while maintaining the unified structure with the friction member.
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 solution allows for cost-effective fixation of friction members and simplifies the attachment process by eliminating the need for axis-alignment, resulting in a lightweight, efficient torque limiter with reduced axial size.
Implementation Method 1
The damper mechanism circumferentially elastically couples the friction coupling plate and the output-side member
Implementation Method 2
the friction members being interposed and held between the transmission torque limiting part and the friction coupling surface of the drive member
Data Source
AI summary
The torque limiter includes a flywheel, a clutch plate, a spline hub, a clutch disc assembly and a transmission torque limiting part. The flywheel includes a friction coupling surface. The clutch plate includes plural axial through holes. Plural friction members are respectively attached to the through holes. The spline hub can be engaged with a transmission-side shaft. The clutch disc assembly circumferentially elastically couples the clutch plate and the spline hub. The transmission torque limiting part limits torque to be transmitted from the flywheel to the transmission-side shaft while the friction members are interposed and held between the transmission torque limiting part and the friction coupling surface of the flywheel.