Torque Limiter Spring Layout for Uniform Contact Force
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Solution Overview
Problem
Existing torque limiters face issues with uneven contact force distribution due to geometrical errors, leading to problems in defining the torque limit and uneven wear.
Innovation Solution
A torque limiter design featuring two cover discs, a central disc, and friction linings, where a spring element is arranged between the central disc and the friction linings to equalize surface pressure, and a disc spring is used to generate the desired contact force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If friction linings, friction plate and/or disc spring are made fully symmetrical to avoid uneven contact force, then manufacturing precision is improved, but device complexity increases and axial installation space is required
Solution Approach 1:
A spring element is introduced as an intermediary component between the friction lining and the disc spring. This spring element acts as a mediator that compensates for geometric errors and asymmetries in the friction components, equalizing the contact force distribution without requiring the friction linings, friction plate, or disc spring to be perfectly symmetrical. The spring element absorbs the irregularities and transmits uniform force to the friction lining.
Solution Approach 2:
The spring element changes the mechanical parameters of the system by introducing elasticity and compliance. It transforms the rigid force transmission into a compliant system that can adapt to geometric variations. The spring element's elastic properties allow it to deform and equalize contact forces dynamically, converting geometric imperfections into elastic deformations that result in uniform force distribution.
2Manufacturing precision
If pressure plates and/or friction plates are set at an angle to compensate for geometrical errors, then contact force distribution is improved, but device complexity increases and axial installation space is required
Solution Approach 1:
The spring element serves as an intermediary that eliminates the need for angular positioning of pressure plates or friction plates. Instead of tilting components to compensate for geometric errors, the spring element absorbs these errors through its elastic deformation, maintaining simple axial alignment while achieving uniform pressure distribution.
Solution Approach 2:
Instead of adjusting the geometry of rigid components (tilting plates) to achieve uniform pressure, the invention inverts the approach by using a compliant element (spring) that actively adapts to geometric variations. The solution moves from rigid geometric compensation to elastic adaptive compensation.
3Reliability
If disc spring exerts high force to ensure torque limiting function, then reliability is improved, but uneven wear occurs due to geometrical errors
Solution Approach 1:
The spring element acts as a protective intermediary between the high-force disc spring and the friction lining. It distributes the high contact forces uniformly across the friction lining surface, preventing localized stress concentrations that would cause uneven wear. This allows the disc spring to exert the necessary high forces for reliable torque limiting while the spring element ensures even force distribution to protect the friction components.
Solution Approach 2:
The spring element provides beforehand cushioning by pre-distributing forces uniformly across the friction lining before operation begins. It creates a compliant interface that prevents direct transmission of uneven forces from the disc spring to the friction lining, cushioning against the potential for uneven wear from the start of operation.
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 proposed design ensures consistent contact force distribution, maintaining a defined torque limit and reducing wear, while also minimizing axial installation space and the number of components.
Implementation Method 1
A spring element is arranged between the central disc and a respective friction lining. The spring element is designed to equalize the surface pressure for the frictionally locking transmission of a torque.
Implementation Method 2
two friction linings which are arranged axially between the central disc and a respective cover disc for the frictionally locking transmission of a torque between the central disc and the respective cover disc
Data Source
AI summary
A torque limiter for a drive train includes a rotational axis, a first cover disc and a second cover disc, a central disc arranged axially between the cover discs, a first friction lining and a second friction lining, a radially outer connector and a radially inner connector, and a spring element. The first friction lining is for frictionally locking torque transmission between the first cover disc and the central disc, and the second friction lining is for frictionally locking torque transmission between the second cover disc and the central disc. The radially outer connector is permanently connected to the cover discs in a torque-transmitting manner, and the radially inner connector is permanently connected to the central disc in a torque-transmitting manner. The spring element is arranged between the central disc and the first friction lining or the second friction lining.