Electromagnetic Single-Plate Clutch Synchronizer for Wear and Vibration
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Solution Overview
Problem
Existing electromagnetic clutch systems in gas turbine engines experience wear and vibration issues during accessory engagement, leading to maintenance challenges and inefficient operation.
Innovation Solution
An electromagnetic clutch assembly with a synchronizer that includes a first and second clutch plate, a synchronizer, a spring, and an electromagnet, where the synchronizer extends through an aperture in the second clutch plate, allowing for controlled magnetic field application to reduce wear and vibration by synchronizing the rotational speeds of the clutch plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical clutch with shear-limited shaft is used to couple driven components to the turbine engine, then the accessory components can be selectively disconnected, but wear occurs on the clutch faces and debris is generated from shearing the shaft
Solution Approach 1:
The synchronizer acts as an intermediary component between the first and second clutch plates. It extends through an aperture in the second clutch plate and contacts the first clutch plate to synchronize rotational speeds before full engagement, reducing wear and preventing debris generation during the coupling process
Solution Approach 2:
The patent replaces the traditional shear-limited shaft mechanical protection mechanism with an electromagnetic clutch system that uses magnetic fields for engagement control. The electromagnet generates magnetic flux through the clutch plates to control engagement, eliminating the need for mechanical shearing to protect the engine
2Device complexity
If the clutch plates are directly engaged without synchronization, then the engagement process is simple, but vibration and wear increase during engagement
Solution Approach 1:
The synchronizer performs preliminary action by synchronizing the rotational speeds of the two clutch plates before full engagement occurs. The synchronizer contacts the first clutch plate and transfers rotational speed to the second clutch plate through the aperture, ensuring smooth engagement and reducing vibration and wear
Solution Approach 2:
The synchronizer serves as a mediator that gradually transfers rotational energy between the clutch plates during engagement, reducing the shock and vibration that would occur with direct engagement while maintaining a relatively simple overall device structure
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 reduces wear on clutch faces, minimizes vibration, and provides smoother engagement, extending the lifespan of the clutch system while reducing maintenance costs through the use of a replaceable synchronizer component.
Implementation Method 1
The electromagnet may be configured to generate a first magnetic field as a first magnetic flux passing through the first clutch plate and the second clutch plate
Implementation Method 2
The spring may be configured to exert a spring force on the synchronizer in a direction toward the first clutch plate
Implementation Method 3
a surface of the synchronizer may be configured to contact the first clutch plate
Data Source
AI summary
An electromagnetic clutch assembly may include a first clutch plate, a second clutch plate, and a synchronizer. The second clutch plate may define an aperture. A portion of the synchronizer may be configured to extend through the aperture. In the absence of a magnetic field, the first clutch plate and the first surface of the second clutch plate may define an air gap and the portion of the synchronizer may extend into the air gap. In response to a first magnetic field, the portion of the synchronizer may contact the first clutch plate. In response to a second magnetic field, the portion of the synchronizer may translate in the aperture toward the second clutch plate and the first clutch plate and the second clutch plate may close the air gap.