Friction Clutch Leaf Spring Self-Intensifying Torque
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Solution Overview
Problem
Existing friction clutches for motor vehicle powertrains require large designs to transmit high torques, leading to increased installation space and assembly costs, and high energy consumption for actuation.
Innovation Solution
A friction clutch design featuring two clutch components with alternately arranged friction elements, supported by a leaf spring unit that applies additional axial force, allowing for high torque transmission with reduced friction element count and installation space, and utilizing a self-intensifying mechanism to maintain low energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the clutch is designed to transmit high torques, then the torque transmission capability is improved, but the installation space and dimensions increase
Solution Approach 1:
The leaf spring unit is designed to automatically generate additional axial force in the drive rotational direction through its set angle configuration. This self-intensifying mechanism eliminates the need for external actuation systems to provide continuous pressing force, allowing the clutch to maintain high torque transmission capability while reducing overall system size and installation space requirements.
Solution Approach 2:
The leaf spring unit is configured with a specific set angle relative to the reference plane, which changes the mechanical parameters of the clutch system. This angular parameter enables the leaf spring to convert rotational drive forces into additional axial pressing force, thereby increasing torque transmission capability without proportionally increasing the clutch dimensions.
2Volume of moving object
If the number and dimensions of friction elements are reduced, then the installation space and assembly cost are reduced, but the torque transmission capability may be compromised
Solution Approach 1:
The leaf spring unit automatically intensifies the axial force on the friction elements during operation through its set angle design. This self-intensifying effect compensates for the reduced number and dimensions of friction elements, maintaining adequate torque transmission capability while allowing for a more compact clutch design with fewer components.
Solution Approach 2:
The leaf spring unit is pre-configured with a set angle that prepares it to generate additional axial force when the clutch is in the closed position. This preliminary configuration ensures that the friction elements receive sufficient pressing force even when reduced in number or size, thereby maintaining torque transmission capability without requiring full-sized friction element sets.
3Use of energy by moving object
If the engagement force and engagement travel are reduced, then the energy consumption of actuators is reduced, but the reliability of engagement may be compromised
Solution Approach 1:
The leaf spring unit's self-intensifying mechanism automatically provides additional axial force during the engagement process, reducing the burden on the actuator. This allows for smaller engagement force and shorter engagement travel requirements, thereby reducing actuator energy consumption while maintaining reliable engagement through the leaf spring's mechanical assistance.
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 design enables efficient transmission of high torques while minimizing installation space and assembly costs, and reduces the energy required for actuator operation, achieving a compact and cost-effective solution.
Implementation Method 1
A leaf spring of the at least one leaf spring unit is designed and positioned relative to a reference plane aligned perpendicularly to the rotational axis in a set angle in the closed position such that an additional axial force is applied to the friction elements of the different clutch components in a drive rotational direction of the first clutch component
Implementation Method 2
The friction elements of the various clutch components may be arranged alternately next to one another in an axial direction of a central rotational axis (of the friction clutch) and in a closed position (of the friction clutch) lie against each other in a frictionally locking manner
Data Source
AI summary
A friction clutch includes a reference plane aligned perpendicular to a rotational axis, a first clutch component, and a second clutch component. The first clutch component has a first friction element, a first support part that receives the first friction element, a leaf spring unit including a leaf spring that rotationally fixes the second support part to the first support part. The second clutch component has a second friction element. The first friction element lies against the second friction element in a frictionally locking manner in a closed position, and is axially spaced from the second friction element in an open position. The leaf spring is designed and positioned relative to the reference plane in a set angle in the closed position such that an additional axial force is applied to the first friction element and the second friction element in a drive rotational direction of the first clutch component.