Brushless Motor Clutch Actuation for Preemptive Engagement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Clutch packs with electromagnetic clutches cannot incorporate a preemptive feature due to the requirement of relative rotation between the base plate and cam plate, which conflicts with the need for stationary components in clutch packs with preemptive engagement, limiting their response time and packaging flexibility.
Innovation Solution
Incorporating brushless motor technology into the clutch assembly, using a rotor and stator with coil windings to provide relative rotation between the cam and base plates, and a sensor for precise control, allowing the clutch pack to be actuated without the need for relative rotation, enabling preemptive engagement and improved response time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an electromagnetic clutch is used to actuate the ball ramp assembly, then the clutch pack can be engaged through relative rotation between the base plate and cam plate, but a preemptive feature cannot be incorporated because the base plate or cam plate must remain stationary for preemptive engagement
Solution Approach 1:
The patent replaces the traditional electromagnetic clutch mechanism with a brushless direct current (BLDC) motor system. This substitution eliminates the need for relative rotation between base plate and cam plate, allowing one component to remain stationary while enabling preemptive engagement through direct motor control of the ball ramp actuator.
Solution Approach 2:
The BLDC motor system serves multiple functions: it provides both the rotational force needed for normal clutch engagement and the precise control required for preemptive engagement. This multi-functional approach allows the same actuator to handle both engagement modes without requiring separate mechanisms.
2Speed
If an electromagnetic clutch is used, then the clutch pack engagement can be achieved, but the response time is limited due to the mechanical rotation requirement
Solution Approach 1:
The BLDC motor system enables preemptive engagement by allowing the ball ramp actuator to be positioned or pre-loaded before actual clutch engagement is needed. This preliminary positioning reduces the time required for full engagement, improving overall response time.
Solution Approach 2:
Replacing the electromagnetic clutch with a BLDC motor eliminates the mechanical constraints of relative rotation, allowing for faster and more direct actuation of the clutch pack. The electronic control of the BLDC motor enables quicker response compared to the mechanical rotation required by electromagnetic clutches.
3Ease of manufacture
If an electromagnetic clutch is used, then clutch engagement is achieved, but packaging requirements cannot be met due to the space and configuration constraints
Solution Approach 1:
The BLDC motor system offers greater packaging flexibility compared to electromagnetic clutches. The motor can be mounted in various orientations and positions, and its compact design allows for more flexible integration into different vehicle configurations. The stationary base plate or cam plate design simplifies the overall packaging arrangement.
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 brushless motor technology allows for precise control of clutch pack engagement, enhancing response time and accommodating packaging requirements by enabling preemptive engagement without the need for relative rotation, thus improving overall vehicle dynamic control.
Implementation Method 1
a rotor and stator with coil windings to provide relative rotation between the cam and base plates
Data Source
AI summary
A clutch assembly which incorporates brushless motor technology to engage a clutch pack to cause two shafts to rotate in unison. The clutch actuation assembly includes a clutch apply member, a base plate disposed about an axis, a cam plate disposed about the axis, and at least one cam, operably associated with the base plate and the cam plate. At least one load transferring member operably associated with the at least one cam, as well as an actuator for providing relative rotation between the cam plate and the base plate about the axis, causing the at least one load transferring member to move with respect to the at least one cam, and the cam plate to translate along the axis actuating said clutch apply member.