Hysteresis Clutch Axial Overlap Adjustment
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Solution Overview
Problem
Hysteresis clutches and brakes face challenges in achieving precise torque control due to manufacturing and material-related fluctuations, leading to scattering of slip torque, and existing solutions are either complex, bulky, or involve high technical effort and risk of irreversible changes.
Innovation Solution
A compact hysteresis clutch design with adjustable axial overlap between permanent magnets and hysteresis rings, using an adjustment method to determine the exact overlap for a specific torque, allowing for precise torque setting with minimal technical complexity and external dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the axial overlap between permanent magnets and hysteresis rings is fixed by structural design, then the clutch structure is simple, but the torque transmission precision deteriorates due to production fluctuations
Solution Approach 1:
The patent introduces an adjustable axial overlap mechanism that allows the coupling between permanent magnets and hysteresis rings to be dynamically adjusted after assembly. This enables torque precision correction without redesigning the entire clutch structure, resolving the contradiction between structural simplicity and manufacturing precision.
Solution Approach 2:
The patent changes the axial overlap parameter as a variable that can be adjusted to compensate for production fluctuations. By making this geometric parameter adjustable rather than fixed, the system can achieve precise torque transmission while maintaining a relatively simple overall structure.
2Manufacturing precision
If machining is used to increase the cylindrical air gap to reduce torque, then the torque control precision is improved, but the surface sensitivity to environmental influences worsens
Solution Approach 1:
The patent performs the torque adjustment action after the clutch is assembled and installed, rather than during manufacturing. This preliminary action (adjustment) is taken at the appropriate time to achieve precise torque control without exposing machined surfaces to environmental damage during the adjustment process.
Solution Approach 2:
The patent replaces the mechanical machining process with a magnetic field-based adjustment mechanism. Instead of removing material to change the air gap, the system uses adjustable magnetic coupling to achieve torque control, eliminating the creation of sensitive bare metallic surfaces.
3Adaptability or versatility
If heating is used to permanently weaken magnetic properties to reduce torque, then the torque adjustment capability is improved, but the risk of irreversible changes and high cost worsen
Solution Approach 1:
Instead of using heat to permanently weaken magnetic properties, the patent inverts the approach by using adjustable mechanical overlap to control the magnetic coupling. This allows torque adjustment without irreversible changes to the magnetic materials, maintaining reliability while achieving adaptability.
Solution Approach 2:
The patent enables the clutch to self-adjust its torque characteristic through a simple mechanical adjustment mechanism that modifies the axial overlap. This self-service adjustment eliminates the need for expensive and risky thermal processing while providing the required torque adaptability.
4Manufacturing precision
If an adjusting device is added to control axial overlap for torque compensation, then the torque precision is improved, but the device complexity and installation space worsen
Solution Approach 1:
The patent merges the adjusting function with the existing clutch structure by integrating the axial overlap adjustment into the bearing or mounting arrangement. This combination eliminates the need for separate, complex adjusting devices while maintaining torque precision.
Solution Approach 2:
The patent addresses the torque control problem by adding adjustment in the axial dimension rather than requiring complex radial or circumferential adjusting mechanisms. This dimensional approach simplifies the adjusting device while achieving the desired torque precision.
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 enables precise control of slip torque with high accuracy and low technical complexity, ensuring reliable torque transmission while minimizing environmental sensitivity and risk of overheating.
Implementation Method 1
a rotational movement is transmitted without contact between a radially inner first hub part equipped with permanent magnets across a cylindrical air gap to a radially outer second hub part equipped with magnetizable hysteresis rings
Implementation Method 2
hysteresis clutches with the features of this patent, a rotational movement is transmitted without contact between a radially inner first hub part equipped with permanent magnets across a cylindrical air gap to a radially outer second hub part equipped with magnetizable hysteresis rings
Implementation Method 3
permanent magnets and the hysteresis rings are arranged axially next to the roller bearing of the clutch and in which the axial overlap between the permanent magnets and the hysteresis rings
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The application describes a hysteresis coupling or brake consisting of a first hub assembly equipped with hysteresis rings and a second hub assembly equipped with magnets. The hysteresis rings and/or the magnets in the hysteresis coupling are designed with sufficient axial clearance to allow for the final adjustment of a desired axial overlap between the hysteresis rings and magnets, resulting in a specific coupling dimension (DK). Furthermore, an adjustment method is described whereby, in a calibration device, the axial overlap of the hysteresis rings and magnets corresponding to a predefined torque, and thus a device dimension (DV), is determined using the hysteresis rings and magnets employed in the hysteresis coupling. The device dimension (DV) is then converted, either directly or by conversion, into a coupling dimension (DK), which defines the final mounting position of the hysteresis rings and magnets in the coupling (Fig. 2).