Electromagnetic Clutch Assembly for Compact Torque Disconnect
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Solution Overview
Problem
Existing drive train systems for motor vehicles lack a compact and easily integratable clutch arrangement with a switch-off function, requiring additional parts and space, and offering limited adaptability in various drive configurations.
Innovation Solution
A compact clutch arrangement featuring a shaft, positive-locking clutch, and electromagnetic actuator with a one-piece gear wheel design, allowing for easy integration and versatile use in various drive configurations, utilizing form-fitting engagement mechanisms and a spring element for actuation, and optionally including a sensor for position detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a clutch arrangement with switch-off function is added to existing drive systems, then torque transmission control capability is improved, but device complexity and installation space increase
Solution Approach 1:
The clutch arrangement merges the clutch body, drive gear, and electromagnetic actuator into an integrated unit. The clutch body and drive gear are combined as a single rotational element, while the electromagnetic actuator is integrated within the housing, reducing the number of separate components and simplifying installation while maintaining full torque transmission control capability.
Solution Approach 2:
The clutch arrangement serves multiple functions within a single device: it provides torque transmission when engaged, torque disengagement when deactivated, and can be integrated into various drive configurations (electric motors, hybrid systems, combustion engines). The electromagnetic actuator provides both actuation force and structural support through its housing.
2Adaptability or versatility
If a clutch arrangement with switch-off function is added to existing drive systems, then torque transmission control capability is improved, but installation space increases
Solution Approach 1:
The electromagnetic actuator is nested within the housing of the clutch arrangement, with its piston extending axially when engaged. The drive gear is integrated with the clutch body, allowing compact packaging of multiple functional elements within a small volume, minimizing the space required for installation while maintaining full control capability.
3Ease of manufacture
If clutch parts and gear wheel are pre-assembled on the shaft as a structural unit, then adjustment effort is reduced, but manufacturing complexity increases
Solution Approach 1:
The clutch body and drive gear are merged into a single integrated component that rotates together on the shaft. This combination eliminates the need for separate adjustment of clutch clearance and gear meshing, reducing installation and adjustment effort while the integrated design simplifies the overall assembly process.
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 provides a compact, efficient, and adaptable clutch system that can be easily integrated into existing drive systems, reducing installation space and adjustment effort, while enabling seamless torque transmission and disengagement, suitable for applications like 48-volt hybrid systems and electric drives.
Implementation Method 1
The actuator is designed as an electromagnetic actuator with an electromagnet and a piston... By generating a magnetic flux, the second clutch element is moved axially
Implementation Method 2
a restoring force is generated by at least one spring element... the spring element acts in such a way that it acts on the clutch in the open position
Implementation Method 3
The first and second engagement means are positively engageable with each other so that the gear and shaft are rotationally fixed to each other... form-fitting engagement between at least two clutch parts
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a clutch assembly for a drive train of a vehicle, comprising: a shaft (3); a gear (15) which is rotatably mounted on the shaft (3) and is supported axially against the shaft (3); a controllable clutch (4) which is designed to transmit torque between the shaft (3) and the gear (15) or to interrupt torque transmission, the clutch (4) having a clutch part (7) which is integral with the gear (15) and an axially movable clutch part (6) which rotates conjointly with the shaft (3), which clutch parts can be brought into interlocking engagement with each other; an electromagnetic actuator (5) for actuating the clutch (4), the electromagnetic actuator (5) having an annular electromagnet (22) which is arranged coaxially with respect to the shaft (3) and is supported axially against a stationary component (12); and a piston (24) which can be moved axially by the electromagnet (22) and is operatively connected to the clutch part (6).