Variable-Turn Wave Spring Alignment for Stable Load Distribution
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Solution Overview
Problem
Existing wave springs do not effectively manage load distribution and are prone to torsional loads and friction-induced issues, leading to improper load application and potential damage to components.
Innovation Solution
The development of wave springs with multiple variable turns, including aligned active and non-active turns, which enhance load distribution and minimize torsional loads through specific alignment of crests and troughs, and the use of counter-clockwise winding to reduce friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wave springs use traditional uniform turn design, then manufacturing is simpler, but load distribution is improper and torsional loads occur
Solution Approach 1:
The wave spring is segmented into multiple turns with different characteristics - some turns are aligned while others are non-aligned. This segmentation allows different portions of the spring to perform different functions, with aligned turns providing specific load distribution and non-aligned turns providing general spring functionality, thereby improving load distribution without requiring complete structural redesign
Solution Approach 2:
Different turns of the wave spring are given different local qualities - specifically, certain turns are designed with alignment while others maintain non-alignment. This local differentiation enables the spring to have varying load-bearing characteristics at different locations, improving overall load distribution while maintaining manufacturing feasibility
2Reliability
If wave springs are wound in traditional direction, then manufacturing is conventional, but friction-induced issues and torsional loads occur
Solution Approach 1:
The wave spring is wound in the opposite direction (counter-clockwise) from the conventional winding direction. This inversion of the winding direction fundamentally changes the friction characteristics and torsional behavior of the spring, reducing friction-induced issues and torsional loads while remaining compatible with standard manufacturing processes
3Reliability
If all turns are aligned to maximize load management, then load distribution improves, but device complexity increases
Solution Approach 1:
Instead of aligning all turns of the wave spring, only a portion of the turns are aligned while others remain non-aligned. This partial action approach provides sufficient load management improvement through the aligned turns while avoiding the excessive complexity that would result from aligning every turn, achieving an optimal balance between performance and simplicity
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 provides improved load management and reduced friction, ensuring consistent load application and minimizing damage to components, thereby enhancing the performance and longevity of applications like automotive e-motors.
Implementation Method 1
a wave spring having multiple variable turns and/or may comprise a total height defined by a first end portion and a second opposite end portion, an intermediate portion disposed between the first and second end portions
Data Source
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AI summary
Wave springs having multiple variable turns, methods of pre-loading components with said wave springs, and methods of manufacturing said wave springs are provided. The wave spring has a total height defined by a first end portion and a second opposite end portion and an intermediate portion disposed between the first and second end portions. The intermediate portion has active turns with waved or non-planar turns and non-active turns with planar or non-waved turns. The wave spring also has a first alignment disposed between the first and second end portions, wherein first alignment comprises at least two waved or non-planar turns being aligned with each other.