Electromagnetic Clutch Radial Position Detection

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Solution Overview

Problem

Existing electromagnetically shiftable positive engagement clutches require indirect measurements for determining the shifting sleeve position, which necessitate additional components, increase installation space, and manufacturing costs, and require precise calibration.

Innovation Solution

A direct measurement method using a Hall sensor adjacent to the shifting sleeve, enclosed by oppositely polarized magnets, detects the shifting sleeve's position radially without additional components, reducing installation space and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If indirect measurement methods are used to determine shifting sleeve position, then additional components can be added to detect position, but installation space increases and manufacturing costs increase

Engineering Contradiction:

Improveshifting sleeve position detection accuracyVSAvoidnumber of additional components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The Hall sensor is integrated into the existing clutch structure, specifically positioned in the sensor recess of the sensor guide plate, merging the measurement function with the existing mechanical components rather than adding separate external measurement systems

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A magnet is attached to the shifting sleeve as an intermediary element that converts the mechanical position of the sleeve into a detectable magnetic field change, allowing the stationary Hall sensor to indirectly measure the moving sleeve's position without direct mechanical contact

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If indirect measurement methods with additional components are used, then position detection is possible, but manufacturing costs increase

Engineering Contradiction:

Improveshifting sleeve position detection accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The magnet on the shifting sleeve serves dual purposes: it is both the actuating element for the clutch engagement and the measurement marker for position detection, eliminating the need for separate measurement components and reducing manufacturing costs

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mechanical indirect measurement systems (such as mechanical linkages or optical systems) are replaced with a magnetic field-based Hall sensor system, which uses electronic sensing instead of mechanical measurement components, reducing part count and manufacturing complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If axial direction position detection is used, then shifting sleeve position can be determined, but installation space increases

Engineering Contradiction:

Improveshifting sleeve position detection accuracyVSAvoidinstallation space

Core Design Contradiction:

Measurement precisionVSArea of stationary object

Solution Approach 1:

The measurement approach transitions from axial direction detection to radial direction detection by positioning the Hall sensor in the sensor recess that faces the shifting sleeve radially, utilizing the radial magnetic field component for position measurement and thereby saving axial installation space

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 method allows precise determination of the shifting sleeve's position with minimal additional space and components, enhancing manufacturing efficiency and reducing costs while maintaining high accuracy.

Implementation Method 1

an axial movement of the shifting sleeve is detected by the Hall sensor through a reduction in the radial gap

Methodology Applied

Scientific EffectHall effect: Hall Effect

Implementation Method 2

at least two magnets that magnetically enclose the at least one Hall sensor and are permanently stationary relative to the at least one Hall sensor

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS20250341239A1Electromagnetically shiftable positive engagement clutch

Publication Date: 2025.11.06 HOERBIGER ANTRIEBSTECHNIK HOLDING GMBH

AI summary

An electromagnetically shiftable positive engagement clutch is shown, having a shifting sleeve which is arranged on a shaft for joint rotation therewith and is linearly displaceable along the shaft between a clutch engagement position and a clutch disengagement position, a clutch body which is aligned coaxially with the shaft, and a stator having at least one energizable drive coil for adjustment of the shifting sleeve along the shaft, wherein in the clutch engagement position there is a positive engagement between the shifting sleeve and the clutch body and thus a rotary connection between the shaft and the clutch body. Moreover, the positive engagement clutch has a stationary sensor device which is arranged adjacent to the shifting sleeve and includes at least one Hall sensor and at least two magnets that magnetically enclose the at least one Hall sensor and are permanently stationary relative to the at least one Hall sensor, with the magnets pointing toward the shifting sleeve and having opposite polarities relative to each other. The sensor device is adjacent to the shifting sleeve in a radial direction so as to be spaced apart therefrom by a radial gap, so that an axial movement of the shifting sleeve is detected by the Hall sensor through a reduction in the radial gap.