Clutch Pack Assembly With Multi-Surface Friction Torque Transfer
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Solution Overview
Problem
Current clutch systems in electric vehicles face inefficiencies in battery usage across speed ranges due to fixed gear ratios, increased weight, and complexity, leading to insufficient synchronization, overheating, and potential damage from high friction forces during transmission.
Innovation Solution
A clutch pack system comprising a push rod assembly, clutch piston, clutch friction plate, outer hub, actuator motor, lead screw shaft, and screw rack gear, which applies pressure through a lever mechanism to ensure stable and efficient power transfer without requiring excessive force, thereby minimizing friction and damage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a synchronizer with a friction cone is used for transmission, then power transfer is enabled, but the friction area is too small to transfer strong torque, causing insufficient synchronization and potential damage
Solution Approach 1:
The clutch friction plate is divided into multiple friction surfaces (first friction surface and second friction surface) arranged in different directions, segmenting the torque transfer function across multiple contact areas rather than relying on a single friction cone surface
Solution Approach 2:
The friction surfaces are arranged in different spatial dimensions (first friction surface in a first direction, second friction surface in a second direction perpendicular to the first), increasing the effective friction area and torque transfer capability by utilizing multi-dimensional contact geometry
2Power
If a synchronizer with a friction cone is used for transmission, then power transfer is enabled, but strong friction force between the shift fork and synchronizer sleeve causes overheating, burning, or damage
Solution Approach 1:
The clutch friction plate segments the friction function into multiple surfaces, distributing the friction force across several contact points rather than concentrating it in a single friction cone, thereby reducing localized heat generation and preventing overheating and burning
Solution Approach 2:
By arranging friction surfaces in different directions and dimensions, the system distributes frictional heat generation across multiple spatial locations, preventing concentrated thermal buildup that would cause burning or damage to the shift fork and synchronizer sleeve
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 system provides stable and durable transmission with reduced risk of overheating or damage, improved battery efficiency, and faster transmission speeds by symmetrically arranging components and utilizing a lever mechanism for pressure application, ensuring reliable power transfer even in abnormal traction motor conditions.
Implementation Method 1
a lead screw shaft connected to the actuator motor, and a screw rack gear configured to perform a linear motion by the lead screw shaft
Implementation Method 2
a clutch friction plate configured to transfer pressure received from the clutch piston, and an outer hub connected to an outer drum by pressure from the clutch friction plate
Data Source
AI summary
A clutch pack system for transmission includes a push rod assembly, a clutch piston configured to transfer pressure received from the push rod assembly, a clutch friction plate configured to transfer pressure received from the clutch piston, and an outer hub connected to an outer drum by pressure from the clutch friction plate.