Friction Clutch Intermediate Element Drag Torque Reduction
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Solution Overview
Problem
Conventional clutches experience power loss and heating due to shear forces in the disengaged state, leading to increased fuel consumption and reduced power availability, as the coupling elements continue to rotate and generate friction in the oil bath.
Innovation Solution
A friction clutch design featuring axially movable coupling elements with an intermediate element that can switch between a locked and free-running state, utilizing an actuator element to manage the coupling elements' rotation, reducing drag torque and heat generation by allowing free rotation in the disengaged state and locking when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If coupling elements are spaced apart with minimal clearance in disengaged state, then switching speed is improved, but power loss and heating increase due to shear forces in oil bath
Solution Approach 1:
The coupling elements are designed to be axially movable relative to each other, transitioning between engaged and disengaged states. In the disengaged state, they can be positioned to minimize contact with the oil bath, reducing shear forces and power loss while maintaining rapid switching capability through the movable design
Solution Approach 2:
An intermediate element is introduced between the coupling elements to control their axial movement. This intermediary component enables precise positioning of the coupling elements to optimize the balance between switching speed and power loss reduction by mediating their relative positions
2Reliability
If coupling elements continue to rotate in disengaged state, then engagement readiness is improved, but drag torque and fuel consumption increase
Solution Approach 1:
The coupling elements are designed to rotate periodically or intermittently rather than continuously in the disengaged state. This periodic rotation maintains engagement readiness by keeping the coupling surfaces prepared while significantly reducing the time-averaged drag torque and fuel consumption compared to continuous rotation
3Loss of energy
If coupling elements are held fixed in disengaged state, then power loss is reduced, but switching response time increases
Solution Approach 1:
The coupling elements maintain a dynamic, movable configuration in the disengaged state rather than being completely fixed. This allows them to be positioned to minimize power loss while retaining the mechanical readiness and low inertia needed for rapid engagement when actuated
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 design significantly reduces drag torque and heat generation, lowering fuel consumption and extending component lifespan, while optimizing installation space and reducing wear and noise.
Implementation Method 1
disk-shaped coupling surfaces, which transmit power between the two sides of the clutch through mutual engagement in engaged or locked state
Implementation Method 2
designed as wet clutches and run in a fluid for lubrication and heat dissipation
Implementation Method 3
run in a fluid for lubrication and heat dissipation
Implementation Method 4
the coupling elements are at a short spatial distance from each other and rotate in opposite directions. Because of the rotation of the coupling elements in the oil bath of the clutch, shear forces arise due to friction with the fluid
Implementation Method 5
shear forces arise due to friction with the fluid. These shear forces cause a drag and thus a power loss of the clutch in the disengaged state
Data Source
AI summary
A friction clutch assembly includes a friction clutch having at least two coupling elements coupled to each other and disposed axially movable with respect to each other. Immediately adjacent coupling elements are each assigned to two sides of a power path defined by the coupling of the at least two coupling elements. An intermediate element is provided on which the coupling elements of one side of the power path are held movably in an axial direction of the coupling elements. The intermediate element is switchable between a locked state and a free-running state. An actuator element opens and closes the friction clutch. In a free-running state, a free rotation of the held coupling elements with respect to the assigned side of the power path is permitted, and in a locked state the held coupling elements are blocked from free rotation.