Electromagnetic Coupling Assembly for Fast, Low-Energy Clutch Actuation
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Solution Overview
Problem
Dynamic Controllable Clutches (DCCs) are complex and have a large number of components, and their hydraulic actuation systems suffer from poor reaction time, limited acceleration, and high energy consumption, especially in hot oil environments, and often require springs for return strokes, limiting their efficiency and reliability.
Innovation Solution
A coupling and control assembly with rotatable coupling members, electromagnetic sources, and a translator that uses springs or permanent magnets to actuate locking members, allowing for magnetic latching to reduce energy consumption and simplify the system by eliminating the need for external actuation systems, and incorporating a stator with inductive coils to control the translator's movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If hydraulic actuation systems are used in DCCs, then the clutch can be actuated, but the reaction time is poor and acceleration is limited
Solution Approach 1:
The patent replaces the hydraulic actuation system with a magnetic field-based actuation system. The stator generates a magnetic field that directly actuates the translator through magnetic forces, eliminating the need for hydraulic fluid, pumps, and valves. This substitution of mechanical/hydraulic systems with a magnetic field-based system resolves the contradiction by providing faster reaction time and acceleration while reducing system complexity.
2Loss of energy
If hydraulic actuation systems are used in DCCs, then the clutch can be actuated, but energy consumption is high
Solution Approach 1:
The patent replaces the energy-intensive hydraulic actuation system with a magnetic field-based system. The stator generates magnetic fields that directly move the translator, eliminating the need for hydraulic pumps and fluid circulation systems that consume significant energy. This substitution reduces energy consumption while also simplifying the actuation system by removing hydraulic components.
3Reliability
If springs are used for return strokes in DCCs, then the system can reset, but component wear increases and reliability decreases
Solution Approach 1:
The patent replaces the mechanical spring-based return stroke system with a magnetic field-based actuation system. The stator can generate magnetic fields in both directions, allowing the translator to be actuated forward and returned to its initial position without mechanical springs. This substitution eliminates wear-prone mechanical components, improving reliability while reducing the overall component count.
4Loss of energy
If magnetic latching is implemented, then energy consumption is reduced, but the system complexity increases
Solution Approach 1:
The patent implements magnetic latching by utilizing the existing stator's magnetic field capability. The stator can generate magnetic fields that not only actuate the translator but also create latching forces to hold it in position. This multi-functionality approach allows the same component to perform both actuation and latching functions, reducing energy consumption without significantly increasing system complexity.
5Adaptability or versatility
If the translator is coupled to rotate with the second coupling member, then bi-directional movement is enabled, but the system becomes more complex
Solution Approach 1:
The patent merges the translator's actuation mechanism with the rotation capability of the second coupling member. The translator is coupled to rotate with the second coupling member, combining linear actuation and rotational movement into a single integrated mechanism. This merging approach enables bi-directional movement capability while minimizing additional complexity by utilizing the existing rotational 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 energy usage, improves vehicle efficiency, minimizes component wear, and enhances noise, vibration, and harshness (NVH) performance by enabling magnetic latching and bi-directional movement with reduced component count and energy consumption.
Implementation Method 1
A stator includes an electromagnetic source
Implementation Method 2
a permanent magnetic source cooperative with the electromagnetic source to translate the translator
Implementation Method 3
The translator may include springs in the passages to actuate the plurality of locking members
Data Source
AI summary
A coupling and control assembly includes first and second rotatable coupling members. The first coupling member has a first coupling face with locking formations, and the second coupling member has a second coupling face with pockets and in opposition with the first coupling face of the first coupling member and a third face spaced from the second coupling face and with passages communicating with the pockets. Locking members in the pockets transmit torque between the first and second coupling members. A stator includes an electromagnetic source, and a translator is translatable, rotatable, and coupled to the second coupling member to be rotatable therewith. The translator may include springs in the passages to actuate the plurality of locking members, or a permanent magnetic source cooperative with the electromagnetic source to translate the translator. An apertured retainer plate may be coupled to the second coupling member to facilitate pivoting of the plurality of locking members.