Clutch Controller Synchronization and Engagement Timing
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Solution Overview
Problem
Claw clutches in hybrid vehicle power trains without synchronization mechanisms face challenges in smoothly switching to an engaged state due to difficulties in accurately matching rotation speeds, leading to increased switching time and actuator size, and repeated spline tooth flipping.
Innovation Solution
A clutch controller system comprising a claw clutch, an actuator, a synchronization controlling unit, and an engagement controlling unit, where the synchronization controlling unit uses an electric motor to adjust the rotation speed of one rotor to match the other, and the engagement controlling unit moves the rotors to engage the teeth before a predetermined rotation speed difference is reached, allowing for smooth engagement without a synchronization mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an electric motor is used to synchronize the rotation speeds of the front and rear of the clutch, then the rotation speeds can be controlled to approach each other, but it is extremely difficult to cause the rotation speeds to completely match, leading to repeated going in and out of the spline tooth
Solution Approach 1:
The engagement controlling unit initiates the movement of the actuator to move the clutch sleeve toward the engagement position before the rotation speed difference between the front and rear of the clutch falls within a predetermined range. This preliminary action ensures that the spline teeth are engaged while there is still a sufficient rotation speed difference, preventing the repeated going in and out of spline teeth that occurs when waiting for complete speed matching.
2Measurement precision
If the rotation speeds are synchronized by using the electric motor, then the rotation speed difference can be reduced, but the switching time increases and the actuator size increases
Solution Approach 1:
The engagement controlling unit determines to move the actuator based on a predicted value of the rotation speed difference and initiates actuator movement before the rotation speed difference falls within the predetermined range. This timing strategy reduces the waiting time for speed synchronization while ensuring engagement occurs at an appropriate moment, thereby reducing overall clutch switching time.
Solution Approach 2:
The synchronization controlling unit continuously monitors the rotation speed difference between the front and rear of the clutch and adjusts the electric motor control accordingly. The engagement controlling unit uses this feedback information to determine the optimal timing for actuator movement, enabling precise control of the engagement process and reducing switching time.
3Measurement precision
If the rotation speeds are synchronized by using the electric motor, then the rotation speed difference can be controlled, but the size of the actuator increases
Solution Approach 1:
By initiating actuator movement before the rotation speed difference falls within the predetermined range, the engagement process is completed more quickly. This reduces the duration and magnitude of forces required during engagement, allowing for a smaller actuator design that can still achieve the required engagement performance.
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
This solution enables smooth switching of the claw clutch to the engaged state, reducing switching time and actuator size, and minimizing power loss by synchronizing rotation speeds and controlling the engagement process to prevent spline tooth flipping.
Implementation Method 1
a synchronization controlling unit that controls an electric motor coupled to the second rotor to control a rotation speed of the second rotor
Data Source
AI summary
A claw clutch includes first and second rotors disposed coaxially with each other, and is switched between an engaged state engaging teeth of the rotors and a disengaged state releasing the engagement. An actuator moves either one of the rotors in an axial direction to switch the clutch between the states. A synchronization controlling unit controls an electric motor coupled to the second rotor to cause its rotation number to approach the rotation number of the first rotor when the clutch is switched to the engaged state. An engagement controlling unit that controls the actuator moves either one of the rotors to a position where the teeth are engaged before a difference in rotation speed between the rotors falls within a predetermined range and the rotation number of the second rotor reaches that of the first rotor when the clutch is switched to the engaged state.