Electromagnetic Actuator for Selectable Coupling Assembly Modes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current clutch systems in vehicular environments face challenges such as overrunning during engine braking, increased manufacturing costs and time due to complex designs, quality defects from external parts, and limited space for control elements, as well as inefficiencies in clutch-position sensing and actuation by electronic control units.
Innovation Solution
A bi-directionally movable actuating shaft with an excitation coil and a controller that receives power and command signals to change the operating mode of a selectable coupling assembly, incorporating a magnetic field sensor for feedback and a microcontroller for control signal generation, allowing for efficient actuation and position sensing without requiring direct power from the electronic control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate selection mechanism is added to the OWC to enable multiple operating modes, then the functionality and versatility of the clutch are improved, but the manufacturing complexity and cost increase due to additional work stations and assembly steps
Solution Approach 1:
The patent combines the selection mechanism with the OWC assembly by integrating the actuator and control elements directly into the clutch structure. The bi-directionally movable actuating shaft is attached to a movable element of the OWC, merging the selection function with the existing clutch components rather than adding a separate external mechanism.
Solution Approach 2:
The actuating shaft serves multiple functions: it acts as both the selection mechanism for different operating modes and as an actuator for engaging/disengaging the clutch. The excitation coil provides both the control field for mode selection and the actuation force for clutch operation, eliminating the need for separate control and actuation systems.
2Ease of operation
If external control elements are mounted on or near the OWC, then the controllability of the clutch is improved, but the manufacturing quality decreases due to additional sources of quality defects
Solution Approach 1:
The control elements (actuating shaft and excitation coil) are integrated into the OWC assembly structure. The actuating shaft is attachable to a movable element of the assembly, and the excitation coil is arranged to be magnetically coupled with the shaft, creating a unified component rather than separate external parts that could introduce quality defects.
3Measurement precision
If the distance between the control element and the actuator is increased, then the control precision is improved, but the available space in the vehicular environment is reduced
Solution Approach 1:
The excitation coil is arranged to be magnetically coupled with the actuating shaft in a compact configuration. The coil surrounds or is positioned adjacent to the shaft, creating a nested arrangement where the control element and actuator occupy overlapping or adjacent spatial volumes rather than requiring separate linear spaces.
4Productivity
If a bi-directionally movable actuating shaft with excitation coil is used, then the actuation efficiency and space utilization are improved, but the device complexity increases due to additional components
Solution Approach 1:
The patent replaces traditional mechanical actuation mechanisms (such as linkages, cams, or direct mechanical connectors) with an electromagnetic system. The excitation coil generates a magnetic field that directly actuates the bi-directionally movable shaft, eliminating the need for intermediate mechanical transmission components and reducing overall system complexity despite adding the coil.
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 enables efficient actuation and sensing of clutch positions, reducing manufacturing costs and time, improving reliability, and enhancing clutch performance by allowing for precise control of clutch modes and position feedback, even in constrained spaces.
Implementation Method 1
An excitation coil is arranged to be magnetically coupled with the shaft and to controllably move the shaft between positions
Implementation Method 2
A magnetic field sensor senses magnetic flux and produces a position feedback signal which is based on the position of the movable element
Data Source
AI summary
An apparatus for controllably actuating a selectable coupling assembly is provided. The apparatus includes a bi-directionally movable, actuating shaft attachable to a movable element of the assembly to provide selective, small displacement element movement to linearly actuate the assembly. An excitation coil is arranged to be magnetically coupled with the shaft and to controllably move the shaft between positions which correspond to different operating modes of the assembly. A controller includes a power inlet terminal adapted to receive electrical power from a vehicle DC power source, a command input terminal adapted to receive a command signal from an electronic control unit and a power switching and supply circuit coupled to the coil to switch and supply received electrical power to the coil based on the command signal. The shaft moves the element and causes the assembly to change its operating mode when the electrical power energizes the coil.