Torque Transmission Module Assembly With Shim-Based Tolerance Adjustment
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Solution Overview
Problem
The assembly of torque transmission modules, particularly triple clutch modules, is complex and costly due to the need for precise alignment and measurement of multiple parts with complex shapes, leading to high manufacturing costs and potential assembly errors.
Innovation Solution
A process involving pre-assembled clutch subsets and a timing element with predefined thicknesses to adjust the positions of the closing cover and clutch subset based on manufacturing tolerances, reducing the number of measurements and parts to be aligned, and using a single timing element to fill the vacant space left by the bearing organ.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple parts with complex shapes are assembled with precise alignment and measurement, then assembly accuracy is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling the clutch subset as a complete unit with all internal parts (input element, output elements, bearing organ) before installation. This pre-assembly is performed with controlled measurements (C1, C2, C3) to ensure proper positioning, eliminating the need for complex on-site alignment of multiple individual parts and reducing assembly complexity while maintaining precision.
Solution Approach 2:
The patent introduces a timing element as an intermediary component with a predefined thickness (C3) that mediates the positioning between the bearing organ and the closing cover. This timing element serves as a spacer that automatically ensures correct axial spacing without requiring complex measurements or adjustments during final assembly, thus improving assembly accuracy while reducing complexity.
2Manufacturing precision
If multiple parts are assembled with precise measurement and alignment, then assembly accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by performing measurements and precision positioning during the pre-assembly stage when parts are easily accessible and can be measured with simple tools. The controlled measurements (C1, C2, C3) are taken during manufacturing rather than during final installation, avoiding costly on-site measurement equipment and reducing overall manufacturing costs while maintaining assembly accuracy.
Solution Approach 2:
The patent standardizes the positioning parameters by defining specific controlled measurements (C1, C2, C3) that must be respected during pre-assembly. By establishing these standardized parameter ranges, the patent enables mass production with consistent quality control, reducing the need for expensive custom adjustments and lowering overall manufacturing costs while ensuring assembly accuracy.
3Ease of manufacture
If bearing organs and closing covers are standardized, then manufacturing cost is reduced, but assembly precision may be compromised
Solution Approach 1:
The timing element with predefined thickness (C3) acts as an intermediary that compensates for variations in standardized bearing organs and closing covers. By introducing this standardized spacer component, the patent ensures that even with standardized parts having normal manufacturing tolerances, the final assembly precision is maintained because the timing element absorbs dimensional variations and ensures correct positioning.
Solution Approach 2:
The patent performs preliminary measurement and selection of the timing element thickness (C3) during the pre-assembly stage, before final installation. This allows for selecting the appropriate standardized timing element that will compensate for any dimensional variations in the bearing organ and closing cover, ensuring assembly precision is achieved even with standardized parts.
Data Source
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AI summary
The invention relates to a method for assembling a transmission module (M), further comprising: - Providing a pre-assembled clutch sub-assembly (2) further comprising a bearing element (90) positioned in support against a torque input element (3), - Providing a cover (50) suitable for being rotationally fixed to an electric machine, - Selecting a shim element (70) according to the dimension chains (C1, C2) of the clutch sub-assembly (2) and the cover (50), configured to respect the manufacturing tolerances of the clutch sub-assembly and the cover, - Positioning the shim element (70) - in the bottom (52) of the closing cover (50), or - on the bearing element (90), or - between the bearing element (90) and the torque input element (3);then permanently assemble the cover (50) to the clutch sub-assembly (2), the shim element (70) being configured so as to adjust the final internal position of the closing cover (50) relative to the clutch sub-assembly by each other, to comply with the manufacturing tolerances of the clutch sub-assembly (2) and the cover (50).