Electromagnetic Clutch Field Core Using Magnetic Paste
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electromagnetic clutches require thicker field cores to increase attractive force, leading to higher manufacturing costs and difficulties, as well as increased weight, which complicates the manufacturing process.
Innovation Solution
A field core unit for an electromagnetic clutch is designed with a magnetic part made of a magnetic paste filled in a field core, featuring an annular-shaped insertion groove for the field coil, allowing efficient magnetic flux flow and reducing leakage, and a molded part to fix the field coil, facilitating weight reduction and manufacturing ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the thickness of the field core is increased to increase attractive force, then the electromagnetic attractive force is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The patent applies composite materials by filling magnetic paste (a composite of magnetic particles and binder) into the field core structure. This creates a composite magnetic system where the magnetic paste enhances the magnetic flux density and attractive force without requiring an increase in the overall field core thickness, thus maintaining weight reduction while improving electromagnetic force.
Solution Approach 2:
The patent changes the magnetic properties parameters by introducing magnetic paste with specific magnetic permeability and flux density characteristics. This alters the magnetic flux distribution and intensity within the field core, enabling enhanced attractive force generation with a thinner field core structure, thereby resolving the contradiction between force enhancement and weight reduction.
2Force
If the thickness of the field core is increased to increase attractive force, then the electromagnetic attractive force is improved, but the manufacturing difficulty and cost increase
Solution Approach 1:
The patent segments the magnetic structure into two distinct components: the field core (providing structural support and magnetic path) and the magnetic paste (providing enhanced magnetic properties). This segmentation allows the field core to be manufactured using conventional press work at standard thicknesses, while the magnetic paste is applied separately through filling processes, thereby simplifying manufacturing and reducing costs compared to manufacturing thick field cores by press forging.
Solution Approach 2:
By using composite materials (magnetic paste filled in the field core), the patent enables enhanced magnetic performance without increasing field core thickness, which keeps the field core manufacturable by conventional press work methods and avoids the need for complex press forging processes required for thick field cores.
3Force
If the thickness of the field core is increased to increase attractive force, then the electromagnetic attractive force is improved, but the productivity decreases
Solution Approach 1:
The segmentation of the magnetic system into field core and magnetic paste components enables parallel manufacturing processes. The field core can be mass-produced by conventional press work while the magnetic paste is applied in a separate filling step, thereby maintaining high manufacturing productivity while achieving enhanced attractive force, unlike the alternative of manufacturing thick field cores by slower press forging methods.
4Loss of energy
If the field core structure is modified to guide magnetic flux, then the leakage flux is minimized, but the device complexity increases
Solution Approach 1:
The magnetic paste, as a composite material with high magnetic permeability, serves as an effective magnetic flux guide within the field core structure. It concentrates and directs the magnetic flux along the desired path, minimizing leakage flux without requiring complex geometric modifications to the field core itself, thereby achieving flux guidance with minimal increase in structural complexity.
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 solution enhances the attractive force by minimizing leakage flux, reduces manufacturing costs, and improves productivity while maintaining performance, achieving a significant increase in attractive force and weight reduction.
Implementation Method 1
a field coil 30 embedded in the pulley 20 and accommodated in a field core 40 such that a magnetic flux is generated according to whether electric power may applied to the field coil 30
Implementation Method 2
a magnetic part provided with an annular-shaped insertion groove encompassing lower and side portions of the field coil such that the magnetic flux flows through the magnetic part
Data Source
AI summary
A field core unit for an electromagnetic clutch can include: a field coil generating a magnetic flux; a magnetic part provided with an annular-shaped insertion groove encompassing lower and side portions of the field coil such that the magnetic flux flows through the magnetic part; and a field core configured such that an upper surface thereof is open and an interior space is formed therein. The magnetic part can be inserted into the field core.