Electromagnetic Dog Clutch with Sector-Shaped Tooth Spaces
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Solution Overview
Problem
Traditional clutches in new energy automobiles are heavy, complex, and prone to noise and alignment issues due to their numerous components, leading to inefficiencies and maintenance challenges, particularly in the engagement and torque transmission between movable and fixed contrate gears.
Innovation Solution
An electromagnetic dog clutch with contrate transmission teeth of uniform thickness and sector-shaped tooth spaces, combined with a damping mechanism and centering sleeve, facilitates easy engagement, maintains coaxial alignment, and reduces noise through a spline power transmission system and copper alloy centering sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rectangular transmission teeth and tooth spaces are used, then the anti-interference ability and torque transmission capability are improved, but the alignment and engagement difficulty increases
Solution Approach 1:
The patent applies asymmetry by designing the tooth spaces with a trapezoidal cross-section where the width varies along the engagement direction. The tooth space width is larger at the entrance and gradually decreases toward the bottom, creating an asymmetric geometry that guides the rectangular teeth into proper alignment during engagement. This asymmetric design provides self-centering functionality, allowing the teeth to automatically align during the engagement process without requiring extremely high manufacturing precision.
2Ease of operation
If the width of tooth spaces is greater than that of teeth, then the engagement process is facilitated, but the contact area is reduced to line contact only
Solution Approach 1:
The patent applies local quality by varying the width of the tooth spaces along the engagement direction. The tooth space width is locally larger at the entrance to facilitate easy engagement and alignment of the rectangular teeth, then gradually decreases toward the bottom of the tooth space. This creates a gradient distribution of width that provides both easy engagement at the entrance and increased contact area at the engagement interface, transforming the contact from pure line contact to a broader surface contact zone.
3Ease of operation
If a spring is used for resetting the movable contrate gear, then the separation function is achieved, but the system noise increases due to collision
Solution Approach 1:
The patent applies beforehand cushioning by introducing a damping mechanism between the movable gear sleeve and the limiting plate. This damping mechanism, which may include damping elements or cushioning structures, is pre-installed to absorb the impact energy when the movable gear sleeve collides with the limiting plate during the resetting process. By providing this cushioning in advance, the patent effectively reduces the collision impact and associated system noise while maintaining the spring-based resetting function.
4Speed
If the movable gear sleeve moves at high speed during engagement, then the response time is reduced, but the collision impact and noise increase
Solution Approach 1:
The patent applies beforehand cushioning by introducing a damping mechanism between the movable gear sleeve and the limiting plate. This damping mechanism, which may include damping elements or cushioning structures, is pre-installed to absorb the impact energy when the movable gear sleeve collides with the limiting plate during the resetting process. By providing this cushioning in advance, the patent effectively reduces the collision impact and associated system noise while maintaining the spring-based resetting function.
Solution Approach 2:
The patent applies the intermediary principle by introducing a damping mechanism as a mediator between the movable gear sleeve and the limiting plate. This damping mechanism acts as an intermediate element that absorbs and dissipates the collision energy, reducing the direct impact between the moving parts. The damping mechanism serves as a buffer that allows high-speed engagement while mitigating the harmful collision effects.
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 enables stable and efficient torque transmission, reduces system noise, and maintains long-term coaxial alignment between the movable and fixed contrate gears, enhancing the clutch's reliability and performance.
Implementation Method 1
under the attraction of the electromagnet the movable contrate gear engages with the fixed contrate gear
Implementation Method 2
the damping mechanism absorbs shock and reduces noise when the limiting plate and the movable gear sleeve collide
Data Source
Figure 1~2
Figure 3~4a
Figure 4b~5b
AI summary
The present invention discloses an electromagnetic dog clutch, comprising a movable gear sleeve and a fixed toothed sleeve that are engaged to transmit power The movable gear sleeve is provided with contrate transmission teeth or tooth spaces, and the fixed toothed sleeve is correspondingly provided with contrate tooth spaces or transmission teeth. The transmission teeth have a uniform thickness in a direction of tooth length, tooth spaces that engage with the transmission teeth have a sector-shape in a direction of tooth space length, and the width of two sides of the tooth spaces gradually increases outwardly along the radial direction of the fixed toothed sleeve and gradually decreases inwardly along the radial direction of the fixed toothed sleeve. By employing the engagement of transmission teeth of uniform thickness and sector-shaped tooth spaces, the transmission teeth can more easily engage with the tooth spaces, and more easily realize surface contact, which facilities moment transmission and facilities the stability of the transmission structure.