Electromagnet Clutch Pack for Compressor Torque Control

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Solution Overview

Problem

Current air compressor clutch systems are inefficient, prone to wear, and costly to manufacture, lacking effective engagement and disengagement mechanisms that minimize vehicle disturbance and optimize compressor operation.

Innovation Solution

The use of an electromagnet-activated clutch pack with a rotor, armature, and ramp plates that translate axially to engage and disengage the clutch pack, allowing for torque transfer between a driven gear and an input shaft, enabling controlled coupling and decoupling for efficient compressor operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional clutch mechanism is used for compressor engagement and disengagement, then the compressor can be activated when needed, but the system suffers from inefficiency, excessive wear, and high manufacturing costs

Engineering Contradiction:

Improveclutch durabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the traditional mechanical clutch mechanism with an electromagnet-actuated system. The electromagnet uses electromagnetic fields to engage and disengage the clutch pack, eliminating complex mechanical linkages, reducing wear through non-contact actuation, and lowering manufacturing costs by using standard electromagnetic components instead of precision mechanical parts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an electromagnet as an intermediary between the control system and the clutch pack. This electromagnet acts as a mediator that converts electrical signals into mechanical engagement forces, providing smoother and more controlled clutch operation while reducing direct mechanical stress and wear on the clutch components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the clutch engages and disengages abruptly, then the compressor can be quickly activated or deactivated, but this causes vehicle disturbance and inefficiency

Engineering Contradiction:

Improvecompressor response timeVSAvoidvehicle disturbance

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent employs dynamic engagement through the electromagnet system, which can gradually build and release magnetic force rather than applying sudden mechanical impact. The electromagnet allows for controlled, progressive engagement of the clutch pack, enabling the compressor to activate or deactivate smoothly without causing abrupt vibrations or disturbances to the vehicle, while still maintaining quick response capability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The electromagnet system provides beforehand cushioning by gradually building electromagnetic force before full engagement occurs. This gradual buildup acts as a cushion against sudden mechanical shocks, allowing the clutch to engage smoothly and prevent vehicle disturbance while maintaining efficient compressor activation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If the clutch pack remains in constant engagement, then the compressor is always driven, but this wastes energy when compressor output exceeds system requirements

Engineering Contradiction:

Improvepressure maintenanceVSAvoidenergy efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent implements feedback control through the electromagnet system, which responds to system pressure requirements. When the pneumatic system reaches maximum desired pressure, the feedback signal deactivates the electromagnet, disengaging the clutch pack and stopping compressor operation. This prevents energy waste from continuous compression while ensuring pressure is maintained when needed, creating an efficient on-demand operation cycle.

Inventive Principle:

Principle #23Feedback

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 solution provides improved efficiency, reduced wear, and cost-effectiveness by enabling soft engagement and disengagement of the compressor, minimizing vehicle disturbance and optimizing air compressor system performance.

Implementation Method 1

The clutch assembly includes an electromagnet, an actuator activated by the electromagnet

Methodology Applied

Scientific EffectElectromagnet: Electromagnet

Implementation Method 2

a clutch pack that is biased into increased frictional engagement by the actuator to transfer the torque from the driven member to the input shaft

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS9422990B2Clutch for linking an input shaft with a drive mechanism and methods of coupling control using the same

Publication Date: 2016.08.23 MUVIQ SRL

AI summary

Drive devices for coupling a drive mechanism to an input shaft and methods of providing coupling control through an electromagnet are described herein. The drive devices include a driven member operatively coupled to a clutch assembly engageable with an input shaft. The clutch assembly includes an electromagnet, an actuator activated by the electromagnet, and a clutch pack that is biased into increased frictional engagement by the actuator to transfer the torque from the driven member to the input shaft. The methods include providing such a drive device and activating the electromagnet.