Wedge Lock Washer Pair With Flat Reaction Washer for Easier Stamping
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Solution Overview
Problem
Existing wedge lock washers made of spring steel are complex and costly to manufacture, and those with conical surfaces are difficult to produce using simple stamping and pressing processes, limiting their application and effectiveness.
Innovation Solution
A pair of wedge lock washers with parallel disk surfaces and varying radial rib heights, allowing for easier production through punching and laser cutting, and featuring an adhesive connection for rotational mobility, ensuring effective form-fitting engagement with components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wedge lock washers are made of spring steel with conical surfaces to achieve form-fitting engagement, then anti-loosening performance is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention divides the washer into two separate components: a conical wedge lock washer and a flat reaction washer. This segmentation allows the conical surfaces to be produced only where needed (in the wedge lock washer) using simpler stamping processes, while the reaction washer remains flat and easy to manufacture. The segmented design maintains the form-fitting engagement functionality while reducing overall manufacturing complexity and cost.
2Manufacturing precision
If conical surfaces are used on both wedge lock washers to ensure proper clamping sequence, then clamping force distribution is improved, but production difficulty increases due to complexity of stamping and pressing processes
Solution Approach 1:
Instead of making both washers conical (which would be complex to manufacture), the invention inverts the approach by making only the wedge lock washer conical and the reaction washer flat. This inversion maintains the necessary clamping force distribution through the conical surfaces in the wedge lock washer while dramatically simplifying the manufacturing of the reaction washer, which can now be produced using simple flat stamping processes.
3Reliability
If radial ribs are made with varying heights to distribute clamping force effectively, then form-fitting engagement is improved, but manufacturing precision requirements increase
Solution Approach 1:
The invention applies local quality by providing varying rib heights only in specific locations where form-fitting engagement is most critical. The wedge lock washer features radial ribs with different heights (first ribs taller than second ribs) at specific positions around the circumference. This localized variation in rib height maintains reliable form-fitting engagement where needed while keeping the overall manufacturing process simpler compared to requiring uniform precision across the entire washer surface.
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 design enables cost-effective manufacturing and enhanced anti-loosening performance by distributing clamping force effectively, reducing material shearing risk and allowing for adjustable clamping force application.
Implementation Method 1
Due to the increased frictional resistance in the release direction between the pair of wedge lock washers and the respective counter support
Implementation Method 2
the clamping structures designed as radial ribs on the surfaces of the two wedge lock washers facing away from each other serve the purpose of increasing friction on the respective counter support surface
Data Source
AI summary
A pair of wedge lock washers with a first wedge lock washer and with a second wedge lock washer. The two washers each have a fastener opening arranged in alignment with one another, a wedge surface structure which engages with one another on their mutually facing surfaces, and clamping structures on their surfaces facing away from one another. One of the two washers has a larger outer diameter than the other washer, and has a rotary drive contour on the radial outside for torque support of a clamping tool. The clamping structures of the washer with the larger diameter are arranged at an axial distance from the disk surface in the inner disk area thereof and are designed for the form-fitting embossing of the same into the surface of a component adjacent thereto. The apexes of the wedge surface structuring are located as positive structures on the mutually facing surfaces of the wedge lock washers in a respective plane. The planes of the disk surfaces of the wedge lock washer with the smaller diameter are arranged parallel to one another.