Hydraulic Transformer Clutch With Electrohydraulic Torque Control
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Solution Overview
Problem
Current dual clutch transmissions face challenges with configuration and assembly complexity, cost, and varying drag torque across different transmission gears, limiting scalability and efficiency.
Innovation Solution
The hydraulic transformer clutch employs radial and axial hydraulic piston assemblies with integrated electrohydraulic actuation, featuring a system of hydraulic cylinders, pistons, and directional control valves to manage torque transfer and reduce oscillations, allowing for scalable and efficient torque distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional dual clutch transmissions use two separate clutches with different configurations, then torque transfer capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges two separate clutch mechanisms into a single integrated clutch assembly that can selectively engage different gear sets. The unified clutch design incorporates multiple friction plates and actuation mechanisms within one structure, eliminating the need for two separate clutch units while maintaining the dual-clutch functionality for odd and even gear engagement.
Solution Approach 2:
The single clutch assembly is designed to perform multiple functions by selectively engaging different gear sets through a common structure. The clutch can operate in different modes (first clutch mode for odd gears, second clutch mode for even gears) using the same basic components, thereby achieving multi-functionality without requiring separate dedicated clutches for each gear set.
2Power
If clutch size is increased to handle higher torque, then torque capacity is improved, but drag torque and energy loss increase
Solution Approach 1:
The clutch design incorporates dynamic elements including spring-loaded actuation mechanisms and adjustable friction plate engagement. The system can dynamically adjust the engagement pressure and contact force based on torque demands, allowing the clutch to maintain adequate torque capacity while minimizing drag torque during partial load conditions through controlled, variable engagement forces.
3Reliability
If wet clutch design is used for higher torque engines, then durability and smooth engagement are improved, but fuel efficiency decreases due to pumping losses
Solution Approach 1:
The patent employs a hybrid approach using hydraulic actuation mechanisms to control the wet clutch engagement. Hydraulic fluid is used to apply controlled pressure to the friction plates for smooth and durable engagement, while the system is designed to minimize fluid volume and pumping requirements. The hydraulic system operates in a controlled manner only during engagement transitions rather than continuous operation, reducing energy losses while maintaining the benefits of wet clutch design.
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 solution provides a compact, cost-effective, and efficient torque transfer mechanism with reduced drag torque variability, enhancing the scalability and performance of dual clutch transmissions.
Implementation Method 1
at least one actuation piston is urged by a solenoid plate that includes an electromagnet solenoid. When an electric current passes the electromagnet solenoid, a generated electromagnetic force pushes the solenoid plate towards a coupling housing
Implementation Method 2
The hydraulic circuit comprises a variable displacement pump, directional control valves, and a hydraulic accumulator that reduces oscillations during clutch actuation
Data Source
AI summary
A hydraulic transformer clutch employs radial hydraulic piston assemblies with integrated electrohydraulic actuation. The hydraulic transformer clutch includes: an output shaft, an output disc affixed to the output shaft for rotation therewith, an input shaft, a rotatable housing affixed to one of the input shaft or the output shaft for rotation therewith, a plurality of hydraulic cylinders, and a plurality of working pistons. The hydraulic cylinders are operatively connected to the rotatable housing, and are spaced about the rotatable housing. Each working piston is slidably mounted within a corresponding hydraulic cylinder of the plurality of hydraulic cylinders, and is positioned to be selectively pushed, when actuated, to create a rigid connection between the input shaft and the output shaft. One or more actuator pistons are pushed by an electromagnet and create pressure that is distributed on working piston surfaces and generates active torque.