Two-Part Middle Piece for Cost-Effective Piston Locking Units
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Solution Overview
Problem
Existing locking units for automatic transmissions, particularly those with a sintered middle piece, face challenges in production cost and functional scope, as they are complex and expensive to manufacture.
Innovation Solution
A locking unit with a two-part middle piece, comprising a metal part for guiding and a thermoplastic part for fluidic conducting and sealing, where the metal part is magnetically soft and the plastic part is injection molded, allowing for a cost-effective and durable configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sintered middle piece is used in the locking unit, then the structural integrity is maintained, but the production cost increases and manufacturing complexity increases
Solution Approach 1:
The middle piece is divided into two separate components: a metal part and a plastic part. The metal part provides structural strength and guides the piston, while the plastic part reduces manufacturing cost and complexity. This segmentation allows each material to be optimized for its specific function, resolving the contradiction between structural integrity and ease of manufacture.
2Strength
If a sintered middle piece is used in the locking unit, then the structural integrity is maintained, but the manufacturing complexity increases
Solution Approach 1:
By segmenting the middle piece into metal and plastic parts, each with specific functions, the manufacturing process becomes simpler. The metal part can be produced using standard metal forming techniques, while the plastic part can be injection molded, both of which are more straightforward than sintering processes required for a monolithic sintered middle piece.
3Ease of manufacture
If a two-part middle piece design is implemented, then production costs are reduced and functional scope is extended, but the device complexity increases
Solution Approach 1:
The metal part and plastic part are combined into a single integrated middle piece assembly that performs multiple functions: the metal part provides structural guidance and magnetic flux path, while the plastic part provides fluid sealing and cost-effective manufacturing. This merging of materials and functions into one assembly reduces overall device complexity despite using two materials.
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 two-part design reduces production costs and extends the functional scope of the locking unit, enabling efficient magnetic flux guidance, secure piston mounting, and effective fluid pressure management while maintaining structural integrity and ease of assembly.
Implementation Method 1
an electromagnet; wherein the at least one detent element interacts with an armature or an armature rod of the electromagnet
Implementation Method 2
the metal part is magnetically soft and the plastic part is injection molded, allowing for a cost-effective and durable configuration
Data Source
AI summary
Disclosed is a locking unit having a piston and serving for locking the movement of the piston which can be acted on with pressure of a fluid. The locking unit can additionally have an electromagnet and at least one detent element. The detent element interacts with an armature or an armature rod of the electromagnet, and the piston has at least one detent receptacle, where the piston can be secured by the retaining interaction of the detent element with the detent receptacle. The piston is adjustable between a retracted position and an extended position. The piston is mounted at least partially in a middle piece which is surrounded at least partially by a housing, and the middle piece is configured in two parts from a metal part and a plastic part.