Axial Single-Coil Linear Actuator for Compact Clutch Packaging
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Solution Overview
Problem
Existing linear actuators for dynamic controllable clutches in automotive transmissions require multiple stator coils and radial orientation, which limits packaging efficiency, actuation force, and copper material usage.
Innovation Solution
An axially oriented linear actuator with a single stator coil and a movable translator, where the stator and translator are axially offset, allowing for higher actuation forces and latching forces, and enabling smaller packaging with reduced copper material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple stator coils are used in radial orientation, then the actuator can provide sufficient actuation force, but the packaging efficiency is limited and copper material usage increases
Solution Approach 1:
The patent transitions from radial orientation to axial orientation of the stator coil, representing a dimensional change in the magnetic field generation approach. This axial configuration allows for more efficient space utilization and reduced copper material usage while maintaining actuation force requirements
2Force
If multiple stator coils are used in radial orientation, then the actuator can provide sufficient actuation force, but the copper material usage increases
Solution Approach 1:
The patent merges multiple stator coils into a single axially oriented coil, combining the functions of multiple components into one. This consolidation reduces copper material usage while maintaining the necessary actuation force through optimized magnetic field generation in the axial direction
3Ease of manufacture
If radial orientation is used, then the actuator structure is conventional, but the packaging efficiency is reduced
Solution Approach 1:
The patent employs axial orientation instead of conventional radial orientation, utilizing a different spatial dimension for magnetic field generation. This dimensional change enables more compact packaging while remaining manufacturable through standard electromagnetic actuator fabrication processes
4Volume of moving object
If axial orientation with single coil is used, then packaging efficiency is improved and copper material is reduced, but the actuator requires new design approach
Solution Approach 1:
The patent changes key parameters including the orientation of the magnetic field (from radial to axial) and the number of coils (from multiple to single). These parameter changes enable compact packaging and reduced material usage while the design complexity is managed through systematic application of electromagnetic principles to the new configuration
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 axially oriented linear actuator provides enhanced actuation and latching forces, improved packaging efficiency, and reduced copper material requirements, making it suitable for dynamic controllable clutches with smaller dimensions.
Implementation Method 1
The translator is movable, depending on polarity of electrical current of the stator coil, along an axial direction between a first position adjacent the stator and a second position away from the stator
Implementation Method 2
the translator may magnetically latch in the first position adjacent the stator by a magnetic loop extending through a stator core of the stator and a permanent magnet of the translator
Data Source
AI summary
An axially oriented, two-position linear actuator includes a fixed stator having a single stator coil and a linear movable translator. The linear actuator is oriented axially in that the stator and the translator are axially offset from one another and the translator is axially movable between first and second end positions toward and away from the stator. For the translator to move between the end positions, the stator coil attracts or repels the translator depending on the polarity of the electrical current of the stator coil. The linear actuator may be part of a clutch assembly, such as a dynamically controllable clutch, for use in controlling coupling members of the clutch assembly.