Electromagnetic One-Way Coupling Flux Bridge Design
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Solution Overview
Problem
Electromagnetic one-way clutches face challenges in minimizing coil size while maintaining sufficient flux generation and avoiding damage from high force and deflection areas, as well as ensuring reliable operation with minimal flux leakage and cost-effective design.
Innovation Solution
The design positions the electromagnet on a static pocket plate, allowing the locking element to be directly acted upon, eliminating dynamic issues, using small coils for cost and space savings, and managing flux gaps to enhance reliability and flux density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil is positioned close to the locking element to minimize size, then coil size and cost are reduced, but the coil is exposed to high force and deflection areas risking damage
Solution Approach 1:
The patent introduces a magnetically permeable bridge structure as an intermediary between the coil and the locking element. This bridge serves as a flux conductor that allows the coil to be positioned away from the high-stress area while still generating sufficient magnetic flux to actuate the locking element. The bridge acts as a mediator that transfers the magnetic force from the safe coil location to the locking element without exposing the coil to damaging forces.
2Loss of energy
If magnetically non-permeable material is used to prevent flux leakage, then flux containment is improved, but flux magnitude may become insufficient to displace the rocker
Solution Approach 1:
The patent applies local quality by creating a magnetically permeable bridge structure at the specific location where flux concentration is needed. Instead of using magnetically non-permeable material throughout, the bridge provides localized magnetic permeability exactly where flux must be concentrated to actuate the locking element. This selective application of magnetic permeability allows flux containment in critical areas while maintaining sufficient flux magnitude for actuation.
3Power
If the electromagnet is located on the cam plate, then flux generation is maximized, but the strut can only be commanded to engage and not disengage
Solution Approach 1:
The patent inverts the conventional arrangement by locating the electromagnet on the pocket plate rather than the cam plate. This inversion allows the electromagnet to interact with the locking element in a way that enables both engagement and disengagement commands. The pocket plate location provides the necessary control versatility while the magnetically permeable bridge ensures sufficient flux generation is maintained.
4Power
If a large diameter coil is used to generate sufficient flux, then flux generation is adequate, but cost, material, weight, and package space increase
Solution Approach 1:
The magnetically permeable bridge acts as a flux concentrating intermediary that allows a smaller coil to generate adequate flux. The bridge concentrates and directs the magnetic flux efficiently to the locking element, eliminating the need for a large diameter coil. This results in reduced coil weight, cost, and package space while maintaining adequate flux generation through the bridge's flux-conducting properties.
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 configuration increases the reliability of the one-way coupling, allows for precise control of engagement and disengagement, reduces material and weight, and minimizes the risk of coil damage while maintaining effective flux generation.
Implementation Method 1
Electromagnetic clutches use electromagnetism to actuate the locking element or strut
Implementation Method 2
When current is applied to a coiled conductor an electromagnet is energized to either engage or disengage the locking element
Implementation Method 3
a bridge made of a magnetically permeable material extending between the locking element and the raceway. The bridge minimizes leakage of flux generated by an electromagnet acting on the locking element
Data Source
AI summary
A one-way coupling includes a cam plate including cams, a pocket plate including pockets, struts, each strut located in one of the pockets, and an electromagnet for engaging one of the struts with one of the cams, including a coil, a core and poles that extend from the coil to said strut, a gap between the poles and the pocket plate exceeding a gap between the poles and said strut.