Clutch Actuator Motor Safety Module for Controlled Engagement
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Solution Overview
Problem
In automated transmissions, unintended rapid clutch engagement due to motor malfunction can lead to hazardous vehicle acceleration, requiring fast driver reaction to avoid accidents, especially when the electric supply to the clutch actuator fails, and existing solutions are costly and lack controlled engagement mechanisms.
Innovation Solution
A safety device using a permanent magnet synchronous motor with a safety module and control module that short circuits the motor coils during a power failure to slow down clutch engagement, employing resistors and energy storage to manage the braking effect, allowing for controlled clutch release without additional mechanical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric motor loses power supply to hold the clutch disengaged, then the clutch spring force causes rapid unintended engagement, but this creates a hazardous situation with no time for driver reaction
Solution Approach 1:
The patent applies preliminary anti-action by detecting motor malfunction conditions before unintended clutch engagement occurs. The control system monitors motor current, voltage, and position to identify failure modes such as power supply loss, then activates safety functions to counteract the harmful effect by controlling the release bearing to prevent rapid clutch engagement, thereby preserving driver reaction time.
Solution Approach 2:
The patent implements preliminary action by continuously monitoring motor parameters (current, voltage, position) during normal operation to detect malfunction conditions before they lead to unintended engagement. The system prepares safety control functions in advance, so when a failure is detected, the control system can immediately intervene to slow down clutch engagement and provide driver reaction time.
2Reliability
If additional mechanical components are added to mechanically lock the motor in disengaged position, then clutch engagement can be controlled, but this increases device complexity and cost
Solution Approach 1:
The patent replaces mechanical locking components with an electronic control system that monitors motor parameters and activates safety functions through electronic control of the release bearing. Instead of adding mechanical locks, the system uses electronic detection of malfunction conditions (current, voltage, position) and electronic control signals to manage clutch engagement, thereby reducing mechanical complexity while maintaining safety.
Solution Approach 2:
The patent enables the existing motor and control system to serve its own safety function by monitoring its own operational parameters (current, voltage, position) and detecting its own malfunction conditions. The control system uses the existing infrastructure to identify failures and activate safety functions, eliminating the need for separate mechanical safety locking components.
3Productivity
If the clutch engagement time is reduced to less than 50-100 ms for fast control, then transmission response is improved, but the driver cannot react to unintended engagement
Solution Approach 1:
The patent implements feedback by continuously monitoring motor parameters (current, voltage, position) during clutch operation and using this information to detect malfunction conditions. The control system receives feedback about the clutch state and motor health, then activates safety functions when abnormal conditions are detected, allowing the system to maintain fast engagement during normal operation while providing protection when failures occur.
Solution Approach 2:
The patent applies dynamics by enabling the clutch control system to adapt its behavior based on operational conditions. During normal operation, the system allows fast engagement for improved productivity. When malfunction conditions are detected through parameter monitoring, the system dynamically switches to a safety mode that controls the release bearing to slow down engagement, thereby adapting the engagement speed to the operational context.
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 effectively slows down unwanted clutch engagement, providing the driver with sufficient time to react and maintain vehicle control during actuator failures, enhancing safety and reducing costs by eliminating the need for extra mechanical components.
Implementation Method 1
A permanent magnet synchronous motor (PMSM) is provided to drive a clutch actuator in an automatic driveline. The PMSM has a rotor with permanent magnets and a stator with at least three coils as phases.
Implementation Method 2
A safety device according to the invention is provided to control the motor and comprises a safety module and a safety control module. The safety module includes switches for each of the coils of the motor, respectively... the coils are shorted and the release of the clutch spring is slower than in a normal power-off situation.
Implementation Method 3
The springs are disposed within a pressure plate assembly which is bolted to the flywheel. A mechanical linkage that controls the pressure plate spring mechanism is usually actuated with an electronically controlled actuator.
Data Source
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AI summary
A safety device comprising a safety module (3) and a safety control module (4) and a method to reduce a speed of an unwanted clutch engagement when a malfunction of a motor (2) for a clutch control actuator occurs (the power supply for the motor is interrupted), so that a driver can have more time to react in such situation.