Electromagnetic Coil System for Reliable Powertrain Disconnect

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Solution Overview

Problem

Existing powertrain disconnect systems in vehicles rely on vacuum power, which is unreliable due to pressure fluctuations and limited availability, and require high energy to operate electromagnetic coils with significant air gaps, leading to inefficiency and component degradation.

Innovation Solution

An electromagnetic pulse disconnect assembly where the electromagnetic coil translates along a central axis toward a stationary armature, reducing the air gap and minimizing energy consumption, allowing precise axial movement and efficient clutching without continuous coil energization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vacuum power is used to operate disconnect systems, then the system can be actuated, but the vacuum level fluctuates with engine throttle settings and altitude, causing unreliable operation

Engineering Contradiction:

Improvedisconnect system operation reliabilityVSAvoidvacuum power availability

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the vacuum-powered diaphragm actuator with an electromagnetic coil assembly that uses electrical energy to generate magnetic force. This substitution eliminates dependence on vacuum pressure fluctuations and provides reliable, controllable actuation through electrical signals, directly resolving the reliability issue caused by variable vacuum conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the actuation parameter from vacuum pressure to electrical current. By controlling the electromagnetic coil through electrical parameters (voltage, current, pulse duration), the system achieves precise and reliable control independent of engine vacuum conditions, altitude, or throttle settings.

Inventive Principle:

Principle #35Parameter changes

2Use of energy by moving object

If electromagnetic coils with significant air gaps are used, then the coil structure is simple, but high energy is required to produce the desired armature movement

Engineering Contradiction:

Improveenergy consumptionVSAvoidair gap distance

Core Design Contradiction:

Use of energy by moving objectVSLength of moving object

Solution Approach 1:

The patent makes the electromagnetic coil itself movable rather than stationary. The coil translates axially to dynamically adjust and minimize the air gap with the armature during actuation. This dynamic adjustment allows the system to achieve effective magnetic coupling with minimal energy consumption, eliminating the need for large stationary coils with fixed air gaps.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The coil is pre-positioned in a retracted state and then translated toward the armature before energization. This preliminary positioning action ensures that when the coil is energized, the air gap is already minimized, requiring significantly less energy to produce the necessary magnetic force for armature actuation.

Inventive Principle:

Principle #10Preliminary action

3Duration of action of stationary object

If the coil is made stationary, then the structure is simpler, but continuous energization is required to maintain armature engagement, causing component degradation

Engineering Contradiction:

Improvecoil energization durationVSAvoidcoil movement mechanism

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

Instead of making the armature move toward a stationary coil, the patent inverts the approach by making the coil move toward the armature. This inversion allows the coil to achieve engagement with minimal air gap through mechanical translation, enabling pulsed rather than continuous energization and reducing thermal stress and component degradation.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The electromagnetic coil is energized in periodic pulses rather than continuously. The coil translates to close the air gap, is energized briefly to actuate the armature, then retracts and de-energizes. This periodic action pattern reduces energy consumption and prevents overheating and degradation of the coil and armature components.

Inventive Principle:

Principle #19Periodic action

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 enhances the reliability and efficiency of disconnect systems by reducing energy usage and preventing component degradation, enabling precise control and operation independent of vacuum power.

Implementation Method 1

responsive to energization of an electromagnetic coil of the electromagnetic coil assembly, translating the electromagnetic coil along a central axis of the electromagnetic coil assembly toward a magnetic armature

Methodology Applied

Scientific EffectElectromagnetic attraction: Electromagnet

Implementation Method 2

electromagnetic coil translates along a central axis toward a stationary armature, reducing the air gap

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS10535458B2Electromagnetic coil system and methods

Publication Date: 2020.01.14 WARN AUTOMOTIVE LLC

AI summary

Methods and systems are provided for operating an electromagnetic coil assembly. As one example, a method comprises responsive to energization of an electromagnetic coil of an electromagnetic coil assembly, translating the electromagnetic coil along a central axis of the electromagnetic coil assembly toward a magnetic armature while maintaining the armature fixed along the central axis. The electromagnetic coil assembly may be utilized within various clutching, braking, or lever applications.