Electromagnetic Clutch Rotor Integration for Axial Overlap Control
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Solution Overview
Problem
The existing rotation transmission devices with electromagnetic clutches are difficult to assemble and have unstable axial overlap distances between the rotor and electromagnet, leading to inconsistent attraction forces and assembly challenges due to manufacturing and assembly errors.
Innovation Solution
The rotation transmission device integrates the electromagnet and rotor as a unit by using a bearing support tube and a small-diameter tubular portion press-fitted into a bearing, allowing simultaneous mounting on the input shaft and enabling easy control of the axial overlap distance, thereby stabilizing the attraction force and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotor and electromagnet are separately mounted on the input shaft, then the assembly process becomes complex and time-consuming, but integrating them into a unit structure increases manufacturing precision requirements
Solution Approach 1:
The patent merges the rotor and electromagnet into a single integrated unit structure. The rotor includes an inner tubular portion and an outer tubular portion, with the electromagnet mounted between them. This integration eliminates the need for separate mounting operations, reducing assembly steps and time while maintaining precise axial overlap distance through the unified structure design.
2Adaptability or versatility
If axial positioning arrangements are spaced apart in the axial direction, then the structure becomes more flexible, but the overlap distance varies due to manufacturing and assembling errors
Solution Approach 1:
The patent employs a nested structure where the electromagnet is mounted between the inner and outer tubular portions of the rotor. The electromagnet's core is positioned within the rotor's tubular structure, creating a compact integrated unit. This nesting arrangement ensures that the axial overlap distance between the rotor and electromagnet remains consistent, as they are positioned relative to each other within the same structural framework rather than being separate components.
3Reliability
If the overlap distance between rotor and electromagnet is not controlled, then the attraction force becomes unstable, but controlling it requires complex positioning mechanisms
Solution Approach 1:
By integrating the electromagnet and rotor into a single unit structure, the patent eliminates the need for complex separate positioning mechanisms. The axial overlap distance is inherently controlled through the integrated design, where the electromagnet is mounted between the inner and outer tubular portions of the rotor. This ensures consistent attraction force without adding complex positioning devices.
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 configuration allows for easy assembly and stable operation by ensuring consistent axial overlap and attraction force, reducing assembly time and preventing damage during disassembly, while also allowing for a smaller electromagnet capacity and increased design freedom.
Implementation Method 1
an electromagnet mounted between the outer tubular portion and the inner tubular portion of the rotor so as to be opposed to the rotor in the axial direction, and configured to apply a magnetic attraction force to the armature that tends to attract the armature to the rotor
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A rotation transmission device includes an electromagnetic clutch (50) including an armature (51), a rotor (52) having an outer tubular portion (52a) and an inner tubular portion (52b), and an electromagnet (53). A bearing support tube (57) is provided at the outer end surface of a core (53b) supporting an electromagnetic coil (53a) of the electromagnet (53). A bearing (58) is mounted in the bearing support tube (57) so as to be axially fixed in position and not to be pulled out of the bearing support tube (57). The small-diameter tubular portion (52c) is provided at the end of the inner tubular portion (52b) of the rotor (52), and press-fitted in the bearing (58) such that the rotor (52) and the electromagnet (53) form a unit. This makes it easier to assemble the electromagnetic clutch (50), and to control the overlap distance between the outer tubular portion (52a) of the rotor (52) and the core (53b) of the electromagnet (53).