Abstract:
Apparatus and method are provided for decreasing frictional effects in stacks of Belleville springs and limiting deflection of the springs. In one embodiment, carriers for springs overlap and minimize the effects of lateral forces that are developed as springs in a stack are loaded. Carriers may be used on mandrel guides, in cylindrical guides or without a guide. In other embodiments, maximum load and defection of springs may be provided by the spring carriers.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates generally to Belleville or disc springs. More particularly, apparatus and method are provided for decreasing friction and hysteresis effects in operation of the springs.  
         [0003]     2. Background of the Invention  
         [0004]     Belleville Springs are conical shaped circular springs that were patented in 1867 by Julian Belleville. They are also called “Belleville Washers,” because in plan view they have the shape of a washer. They are also called “disk springs.” Subsequent improvements have advanced this simple spring device to a sophisticated energy storage system that is used in many mechanical systems today. The springs are designed to be loaded in the direction perpendicular to the washer, i.e., by compressing the cone, and they may be loaded statically or dynamically. Disk springs are used, for example, in brakes, clutches, valves, shock absorbers, actuators, loading of flange joints, and in a variety of mechanical equipment for use in wells, such as jars, accelerators, shock subs, clutches, drilling motors and other equipment.  
         [0005]     Belleville springs (disk springs) are available in a wide range of sizes, from about 8 millimeters to about 800 or more millimeters. When multiple springs are used together, they are usually used with a mandrel inside the springs or a cylindrical surface in contact with the outside periphery of the springs to serve as a guide, so they can be maintained in alignment when a load is applied. They may be delivered pre-assembled in stacks with the guiding device. Combinations of disks having different spring characteristics may be combined in a stack to produce a wide variety of load-deflection curves. The disks may be selected to provide specific load-deflection diagrams. Individual disks may be externally slotted or internally slotted to produce a load-deflection characteristic for specific applications. The disc blanks may be manufactured by stamping, fine blanking or plasma arc/flame cutting and they may receive a variety of metallurgical treatments.  
         [0006]     Design equations are readily available for any combinations of disk springs. Stacks may be made up of springs in parallel or series configuration. In the parallel configuration, springs are arranged in parallel, i.e., with the cone in the same direction. In the series configuration, the external circumference of springs is in contact with that of an adjoining spring and the internal circumference is likewise in contact with that of an adjoining spring. It is possible to generate characteristic curves for stacks of springs by combining parallel stacks with a selected number of disc springs and series configurations of other springs. A manual published by Mubea Tellerfedern und Spannelemente Gmbh of Daaden, Germany, provides information on design theory and properties of Belleville springs and stacks of Belleville springs.  
         [0007]     In addition to disc spring stacks having a mandrel or cylinder as a guide, self-centering disc spring stacks are available. These may be centered by balls and grooves on the inner and outer diameter. The self-centering is primarily used on stacks of large disc springs. Wire-centered disc spring stacks have also been used, substituting wire segments for the steel balls. Friction is slightly higher with this type centering. A T-ring or retaining ring may also be used for centering disc spring stacks.  
         [0008]     It has long been known that friction is important during operation of Belleville springs. The friction may arise between individual springs, between the springs and the guide element, and at the edges of the spring where load is applied. This friction results in a variation between the calculated characteristic load curve and an actual load curve. The force required to compress the springs is greater than the force recovered when the springs are relaxed, which means that a load-deflection diagram exhibits hysteresis. The area within a hysteresis loop is indicative of the effect of friction on operation of the spring system.  
         [0009]     One of the sources of friction in operation of a Belleville or disc spring is the friction between the central and outside peripheries of the spring and the load surfaces coming in contact with those faces. U.S. Pat. No. 3,261,598 discloses mechanisms to minimize the frictional losses from radial movement of a Belleville washer between two flat surfaces. Spring supports that may be deflected with minimal force in a radial direction are employed. The spring supports may be applied at both the central opening and the outside periphery of a Belleville spring.  
         [0010]     U.S. Pat. No. 3,375,000 addresses a different source of frictional losses in stacks of Belleville springs. It discloses a Belleville spring assembly for reducing surface friction between springs that are mounted in a parallel stacked array. A bearing element between the inner and outer edges of adjacent discs is employed. The patent states that stacked arrays of parallel discs in abutting relationship produce undesirable hysteresis losses as a consequence of friction imposed by contacting surfaces through flexure of the washers and associated parts.  
         [0011]     U.S. Pat. No. 3,873,079 discloses a number of Belleville spring discs held in coaxial relation by inner and outside split retainer rings that are expansible by the springs when the springs are deflected axially and spread at their periphery. The retainer rings have v-shaped grooves for receiving the edges of the springs while affording a clearance space to minimize friction during deflection of the springs.  
         [0012]     U.S. Pat. No. 5,081,328 describes one of the wide varieties of applications of Belleville springs—the use in a switch. The patent also describes the limitations of Belleville springs because of frictional effects, explaining that the motion required to convert fluid pressure to mechanical work results in Belleville springs bending, sliding, scraping and plowing at the inside diameter or outside diameter of the springs. The result of friction increases hysteresis and causes an increase in a switch&#39;s “deadband” (the difference between the point of operation and the point that it returns to its pre-operated state). The &#39;328 patent discloses avoiding the difficulty of the Belleville springs (because of frictional effects) by using a pressure-sensing negative rate membrane.  
         [0013]     In stacks of springs guided by a rod or mandrel, springs may be designed with a special inner edge contour in an attempt to minimize friction between the guide rod and the disc springs. However, deviations in geometry of individual disc springs result in an uneven transmission of load from one spring to the next in a stack. This results in forces tending to cause a lateral displacement of the springs, or a buckling of the stack, causing the springs to be pressed with force against the guide element. This lateral force is similar to a buckling force observed in a rod or tube with ends under compression. Thus, there is a need for apparatus and method to minimize the net frictional effects arising from lateral forces or buckling. This will reduce the overall effect of friction on operation of stacks of Belleville springs, whether the springs are guided by a mandrel or a sleeve.  
         [0014]     When Belleville springs are used in downhole jars, for example, friction force on the springs prevents a constant triggering load of the jar. This is discussed in Pub. No. U.S. 2005/0092495, at page 6, col. 1. The referenced publication is hereby incorporated by reference herein in its entirety.  
         [0015]     It is sometimes necessary to include a stroke-limiter with a Belleville spring. For example, if the spring is deflected beyond a certain limit, it may reverse direction, or excess deflection may cause permanent change in spring characteristics. Therefore, there is a need for apparatus to prevent excessive deflection of a Belleville spring along with the reduction of the effects of friction on operation of stacks of Belleville springs.  
       SUMMARY OF INVENTION  
       [0016]     Apparatus is provided for reducing friction during operation of a stack of Belleville springs. The apparatus reduces lateral force on the springs in a stack (two or more springs) by providing a plurality of slidably coupled spring carriers between the springs and their guide mechanism. Apparatus is also provided for limiting deflection of Belleville springs. In other embodiments, no guide is provided and initial overlapping of spring carriers acts as a guide. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]      FIG. 1A  is a perspective view of a Belleville spring.  FIG. 1B  identifies dimensions of a Belleville spring in a cross-sectional view.  
         [0018]      FIG. 2A  is a cross-sectional view of a stack of Belleville springs in series in an uncompressed state on spring carriers and a mandrel guide.  FIG. 2B  is a cross-sectional view of the stack in a compressed state.  FIG. 2C  is a perspective view of springs of the stack and a spring carrier on a mandrel guide.  
         [0019]      FIG. 3A  is a partial cross-sectional view of a stack of Bellville springs in series in an uncompressed state on stroke-limiting spring carriers and a mandrel guide.  FIG. 3B  is a partial cross-sectional view of the stack in a compressed state.  
         [0020]      FIG. 4A  is a cross-sectional view of a stack of Belleville springs in series in an uncompressed state on overlapping spring carriers and a mandrel guide.  FIG. 4B  is a cross-sectional view of the stack in a compressed state.  FIG. 4C  is a perspective view of springs of the stack and spring carriers on a mandrel guide.  
         [0021]      FIG. 5  is a cross-sectional view of a stack of Bellville springs in series in an uncompressed state in overlapping spring carriers in a cylinder guide.  
         [0022]      FIG. 6A  shows dimensions of Belleville springs in series in an uncompressed state on overlapping spring carriers.  FIG. 6B  shows the same springs in a compressed state.  
         [0023]      FIG. 7A  shows a cross-sectional view of a stack of Belleville springs in series in an uncompressed state on overlapping spring carriers.  FIG. 7B  shows the stack in a compressed state. 
     
    
     DETAILED DESCRIPTION  
       [0024]      FIG. 1A  shows a perspective view of a Belleville Washer. The washers are manufactured using materials, such as alloy steels, to meet specific material requirements. They should exhibit good fatigue life and minimum relaxation. A high alloy content material is commonly used as the spring steel.  FIG. 1B  identifies dimensions of Belleville Springs commonly used. Spring  10  is shown in  FIG. 1A  and  FIG. 1B . D 1  is the diameter of the opening, D 2  is the external diameter of the spring, t is the thickness of the spring material, d is the maximum deflection of the spring when it is compressed, and e is the overall thickness of the spring in the uncompressed state. d=e−t. The spring may contain special properties for corrosion or other properties and may be coated with a number of different materials such as phosphate, galvanizing, mechanical zinc plating and electroless nickel plating. It may also be coated with the coating to minimize friction, which is discussed further below.  
         [0025]     Referring to  FIG. 2A , spring stack  20  is shown in cross section, including springs  22  in series configuration on spring carriers  24 , which are guided by mandrel  26 . Forces are applied to the springs through load ring  28 ( a ) and load base  28 ( b ). Referring to the inset of FIG.  2 A, spring carrier  24  is formed by sleeve  21  and circumferential flange  25 .  FIG. 2B  depicts spring stack  20  in the state of maximum compression. Springs  22  have been deflected to the point where the cone is collapsed (i.e., deflected by the distance “d” of  FIG. 1B ). Spring carriers  24  are in contact on mandrel  26 .  FIG. 2C  shows a perspective view of the washers and spring carrier  24  of  FIGS. 2A and 2B . Carrier  24  is formed from sleeve  21  and circumferential flange  25  on the outside surface of the sleeve. Flange  25  allows the washers to be spaced at a selected location on carrier  24 , normally at an equal distance from each end of the sleeve. Spring carrier  24  is adapted to fit slidably on mandrel  26 . The outside diameter of spring carrier  24  is adapted to fit in the inside diameter (D 1  of  FIG. 1B ) of Belleville Spring  22 .  
         [0026]     Referring to  FIG. 3A , Belleville Springs  32  on one side of mandrel  36  are shown in a partial cross-sectional view. Spring carrier  34  is placed between mandrel  36  and springs  32 . Spring carrier  34  includes sleeve  31  and circumferential flange  35 . In  FIG. 3A , springs  32  are either in a relaxed state or in a compressed state less than maximum compression.  FIG. 3B  shows spring  32  in the state of maximum compression allowed when springs are employed on spring carrier  34 . Spring carrier  34  has an axial dimension, as measured from flange  34  to an end of sleeve  31 , greater than the maximum deflection (“d” of  FIG. 1B ) of spring  32 . When the apparatus is deployed on mandrel  36  and load is applied, spring carrier  34  may serve to limit the deflection and the load applied to springs  32 . This load-limiting feature may be selected over a broad range of load from zero deflection or the relaxed state to maximum deflection of the springs. The width of circumferential flange  35  may also be selected to maintain an optimum spacing of springs  32 . Flange  35  serves primarily to control the placement of springs  32  on spring carrier  34 . It preferably has enough width to provide the needed mechanical strength of the flange.  
         [0027]     Referring to  FIG. 4A , springs  42  are deployed on mandrel  46  using spring carriers  44 . As seen more clearly in the center inset, spring carrier  44  is made up of sleeve  41 . The smaller diameter of the inside surface of sleeve  41  is sized to fit slidably over mandrel  46  and the larger diameter of the outside surface of sleeve  41  is sized to fit in the inside diameter of springs  42 . Spring carrier  44  has inside and outside surfaces of different diameter on each side of shoulders  47 ( a ) and  47 ( b ), which are placed at selected locations on the outside surface and inside surface, respectively, of carrier  44 . Shoulder  47 ( a ) separates a larger and small diameter on the outside surface and shoulder  47 ( b ) separates a larger and smaller diameter on the inside surface of sleeve  41 . Circumferential flange  45  may be used to facilitate placing springs  42  on carrier  44 . Load ring  48 ( a ) and load base  48 ( b ) may be used to apply load to stack  40 .  
         [0028]     The outside diameter of one segment of carrier  44  is selected to fit in the inside diameter of another segment of carrier  44 . The carriers are disposed on mandrel  46  such that adjacent carriers overlap and thereby decrease lateral or bucking loads on mandrel  46  as springs  42  are compressed. Overlapping of adjacent carriers creates rigidity to the stack of carriers and provides significant friction reduction in stack  40  as it is compressed and decompressed. A hysteresis curve for the compression and decompression will have significantly smaller area in the presence of overlapping carriers  44  than in the absence of such carriers. Carriers  44  may be truncated so that an end carrier may allow the end spring to compress against load ring  48 ( a ) or load base block  48 ( b ). Truncated carriers  49  (upper inset and lower inset) illustrate a preferred configuration of a spring carrier to be placed at the end of a stack.  
         [0029]     In  FIG. 4B  compressive load has been applied to deflect springs  42  to the point where adjacent springs carriers  44  are completely interlocked or overlapping and springs  42  have reached maximum deflection. Spring carriers  44  have moved along their axis as each spring has been deflected a distance equal to the maximum deflection (“d” of  FIG. 1B ). As discussed above with respect to  FIGS. 3A and 3B , the distance from an end of sleeve  41  to shoulder  47 ( a ) or  47 ( b ) may be less than the maximum deflection of spring  42 . In this case, when the apparatus is deployed on mandrel  46  and load is applied, then spring carrier  44  may serve to limit the deflection and the load applied to springs  42 . This load-limiting feature may be selected over a broad range of load from zero deflection or the relaxed state to maximum deflection of the springs.  
         [0030]     Referring to  FIG. 4C , a perspective view is shown of springs  42  on carriers  44  and mandrel  46 . Sleeve  41  has shoulder  47 ( a ) on the outside surface and shoulder  47 ( b ) on the inside surface. Circumferential flange  45  is placed at a selected position, preferably in the center of the larger diameter surface on the outside surface of sleeve  41 . Shoulders  47 ( a ) and  47 ( b ) may be placed equal distances from the opposite ends of sleeve  41 . Alternatively, the shoulders may be placed at different distances from the opposite ends of sleeve  41 . These distances will be shown in more detail in  FIG. 6A .  
         [0031]     Referring to  FIG. 5  spring stack  50  guided by cylinder  56  is shown. Springs  52  are sized to fit the inside diameter of spring carriers  54 . The larger outside diameter of spring carrier  54  is sized to slidably fit inside cylinder  56 . Spring carriers  54  are made of sleeve  51  (see inset) and have circumferential ledge  55  on the smaller diameter area of the inside surface. Carriers  54  also have shoulders  57 ( a ) and  57 ( b ) at selected locations, similar to the carriers to be placed over a mandrel as shown in  FIG. 4A . Load blocks  58 ( a ) and  58 ( b ) transmit force to the stack of springs  52 .  
         [0032]     Overlapping spring carriers for use inside a cylinder guide or on a mandrel may be designed to provide complete interlocking or overlapping when springs reach maximum deflection or may be designed to provide load-limiting capabilities by selection of axial dimensions.  FIG. 6A  illustrates dimensions of overlapping carriers. As can be noted in the figure, for the carriers to be moved with the springs to maximum spring deflection (d) when the carriers are completely overlapping or interlocked, dimensions may be selected such that: 
 
2 t+w=c+l+r,   (Eq. 1) 
 
 where t is spring thickness, w is width of the circumferential ledge, c is the distance between the inside and outside shoulders, l is the overlap of the carriers at the initial deflection of the springs and r is the remaining overlap from the initial deflection of the springs. If we dimension the spring carrier so that r=2d, then: 
 
2 t+w=c+l+ 2 d.   (Eq. 2) 
 
 The carriers then would move from the position shown in  FIG. 6A  to that shown in  FIG. 6B  (completely overlapping) if 
 
 w=c+l+ 2( d−t ).  (Eq. 3) 
 
 d and t are spring properties that will be supplied by the manufacturer of the selected spring. c and l are design options for the carriers, which will determine the value of w if the springs are to reach maximum deflection when the carriers are completely interlocked. If load-limiting of the springs is to be provided by the carriers, the value of r (along the inside surface) under no-load conditions may be decreased, for example. Alternatively, dimensions of the carriers may be adjusted along the outside surface. 
 
         [0033]     Preferably, the spring carriers disclosed herein are coated with an anti-friction coating. Many such coatings are available. A suitable coating is provided by The Kolene QPQ Process, which is a product of Kolene Corporation. Another suitable process is the Armorall process. Other known friction-reducing coatings, polymers, oils or additives may be used.  
         [0034]     Embodiments disclosed heretofore employed a guide for the springs, either a mandrel or a cylinder. In other embodiments, a guide is not employed and the carriers are placed such that overlapping of adjacent carriers is sufficient to form a rigid structure that prevents sidewise movement of springs or buckling of a stack of springs.  FIG. 7A  illustrates such a stack, stack  70 . Springs  72  are deployed on spring carriers  74 . Note the absence of a mandrel, but adjacent carriers overlap sufficiently to provide a rigid structure, preventing buckling of the stack of springs. Overlapping may be provided by pre-loading springs or by adjusting carrier dimensions to allow sufficient overlapping a zero spring deflection. Carriers  74  have inside and outside surfaces of different diameter on each side of shoulders, as explained above for  FIG. 4A . Circumferential flange  73  facilitates placing springs  72  on carriers  74 . End pieces  78 ( a ) and  78 ( b ) may be used to apply force to the stack and to confine lateral movement of the end pieces of the carriers.  FIG. 7B  shows stack  70  in the totally compressed state. Stack  70  of  FIG. 7  is similar to stack  40  of  FIG. 4 , except a mandrel guide is not present in  FIG. 7 .  FIG. 5  shows a stack using a cylinder as a guide. Of course, a stack can be formed using the guides of  FIG. 5  without a cylinder guide if carriers are initially overlapped. Such a stack may have the guide and spring configuration of  FIG. 5  with load blocks at the ends of the stack and no cylinder guide outside.  
         [0035]     Although the present disclosure has been described in detail, it should be understood that various changes, substitutions and alterations can be made thereto without departing from the scope and spirit of the invention as defined by the appended claims.