Friction Clutch Magnet Segmentation for Radial Space Reduction
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Solution Overview
Problem
Existing friction clutches for vehicle auxiliary units with internal combustion engines are bulky and inefficient in terms of magnetic effect, due to double wall assemblies that increase radial width and material costs.
Innovation Solution
A compact friction clutch design featuring a magnet body that completely covers one axial side of the coil body, with minimal coverage of other outer portions, and a conductive body that covers the magnet body on opposite sides, allowing for improved magnetic flux and reduced radial construction space, utilizing a layered magnet body for cost-effectiveness and adjustable magnetic strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a magnet body completely encloses the coil body on three sides in a U-shaped manner, then the magnetic flux is enhanced, but the radial width and construction space increase
Solution Approach 1:
The magnet body is divided into two separate magnetizable bodies instead of a single enclosing structure. One magnetizable body is positioned on one side of the coil body, and another magnetizable body is positioned on the opposite side, creating a segmented magnetic circuit that reduces radial width while maintaining flux effectiveness
Solution Approach 2:
The magnetic circuit is reconfigured from a radial arrangement (U-shaped enclosure) to an axial arrangement (opposite sides of coil body). This dimensional change allows the magnetic flux to pass through the coil body along the axial direction, reducing the radial width requirement while maintaining the enclosing magnetic effect
2Strength
If double wall assemblies are used in the electromagnet assembly, then structural strength is improved, but material costs and weight increase
Solution Approach 1:
The unnecessary double wall assembly is removed from the electromagnet structure. The patent uses a simplified single-wall construction where the coil body is supported by a single robust wall structure, eliminating redundant material while maintaining sufficient structural strength for the application
Solution Approach 2:
Instead of using double wall assemblies throughout the entire structure, the patent applies localized reinforcement only where structurally necessary. The single wall structure is designed with optimized thickness and support distribution to provide adequate strength without the weight penalty of universal double-wall construction
3Strength
If the coil body is completely enclosed by magnet body, then magnetic effect is optimized, but manufacturing complexity and material usage increase
Solution Approach 1:
The magnet body is segmented into separate magnetizable bodies positioned on opposite sides of the coil body rather than a single enclosing structure. This segmentation simplifies manufacturing by allowing independent fabrication and assembly of smaller components, reducing overall manufacturing complexity while maintaining the magnetic enclosing effect
Solution Approach 2:
Instead of enclosing the coil body with a magnet body from the outside, the patent positions magnetizable bodies on opposite sides of the coil body with the magnetic flux passing through the coil body. This inverted approach achieves the magnetic enclosing effect with simpler manufacturing requirements
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 design achieves a smaller radial construction space with enhanced magnetic flux, reducing material costs and weight while maintaining functionality, and allows for a more compact and efficient electromagnetically actuatable friction clutch.
Implementation Method 1
when the coil is energized, a magnetic field having magnetic field lines can be generated
Implementation Method 2
the magnetic field lines pass through the magnet body and a magnetizable conductive body adjacent to the magnet body, such that a displaceable magnetizable armature portion can be brought from one position into another position
Implementation Method 3
The armature portion is able to be brought, in particular, from a position which is separated from the conductive body into a position which is frictionally connected to the conductive body
Data Source
AI summary
A friction clutch having an electromagnet assembly including a coil and a magnet connected to the coil. When the coil is energised, a magnetic field is generated and passes through the magnet and a magnetisable conductive body adjacent to the magnet, such that a displaceable magnetisable armature portion can be brought from one position into another position. The coil has a plurality of outer portions each having an associated outer dimension of the outer portion. The magnet completely covers an outer portion of the coil by a magnet side. Two further outer portions of the coil are not covered by the magnet or are not covered by more than 20% of an outer dimension of the further outer portion, or wherein, in the case a single further outer portion covered by the magnet, the outer portion is not covered by more than 70%.