Decoupler Shaft Ramp Angle Optimization for High Speed Generator Clutch
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Solution Overview
Problem
Existing generator clutch designs require high forces at high shaft speeds due to a large ramp angle in the sliding clutch member, which complicates decoupling operations.
Innovation Solution
A clutch member with a ramp angle of 6.2° to 6.4° and a complementary angled actuation yoke, allowing for reduced axial movement forces during decoupling, and incorporating splines and a spring for engagement and packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large ramp angle (7°) is used in the sliding clutch member, then the decoupling mechanism can effectively cam the clutch member away from the input shaft, but high forces react at the engaging ramp and yoke faces during high-speed decoupling operations
Solution Approach 1:
The patent applies parameter changes by modifying the ramp angle from the conventional 7° to a smaller angle between 5.5° and 6.5° (preferably 6.0°). This parameter optimization reduces the separating load and axial forces during decoupling operations while maintaining effective camming action, directly resolving the contradiction between decoupling effectiveness and force reduction at high speeds
2Force
If the ramp angle is reduced to lower separating forces, then high-speed decoupling becomes more feasible, but the axial movement distance may be reduced
Solution Approach 1:
The patent compensates for reduced axial movement distance caused by the smaller ramp angle by optimizing the axial travel distance of the actuating yoke and the geometry of the ramp surface. The combined effect of the optimized ramp angle and increased axial travel ensures sufficient decoupling movement while maintaining lower separating forces throughout the operation
3Speed
If a smaller ramp angle (6.2°-6.4°) is used, then forces during decoupling are reduced enabling higher rotational speeds, but the ramp surface area increases
Solution Approach 1:
The patent accepts the increased ramp surface area as a necessary trade-off for reducing the ramp angle to 6.2°-6.4°. This parameter change enables lower separating forces and higher rotational speeds, and the increased surface area is compensated for through optimized material selection and thermal management strategies that handle the additional contact area
Data Source
AI summary
A clutch member for use in a generator clutch has actuation structure including a face with a ramp. The ramp has a ramp angle of between 6.2° and 6.4°. The clutch member may be a sliding decoupler shaft. In addition, a rotor and a generator including the clutch members are also disclosed and claimed.