Integrated Stator Disk Torque Device Using Segmented MR Fluid Shear
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Solution Overview
Problem
Magnetic field controllable devices, such as MR brakes and clutches, face challenges in generating sufficient torque without increasing device size or cost, particularly in compact applications.
Innovation Solution
The integration of multiple stator disks and rotors with a magneto-responsive material and a coil configuration that generates resistance across multiple shear areas, increasing torque generation without enlarging the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the size or diameter of an MR device is increased to generate more torque, then the torque generation capability is improved, but the device becomes more impractical, costly, and problematic for space-constrained applications
Solution Approach 1:
The device is segmented into multiple rotors (first rotor and second rotor) and multiple stators (first stator and second stator) arranged in series. This segmentation allows the creation of multiple shear areas within a compact volume, enabling increased torque generation without proportionally increasing device size. Each rotor-stator pair contributes to the overall torque output, achieving multiplicative torque enhancement within a constrained envelope.
Solution Approach 2:
The invention transitions from a single-plane shear area to a multi-plane three-dimensional arrangement of rotors and stators. By stacking multiple rotor-stator assemblies along the axial direction, the device creates multiple shear areas in series, effectively utilizing the third dimension (axial length) to increase torque capacity without expanding the radial footprint, thus maintaining compactness while enhancing force output.
2Force
If the size of an MR device is increased to generate more torque, then the torque generation capability is improved, but the cost increases
Solution Approach 1:
The device is segmented into multiple rotors (first rotor and second rotor) and multiple stators (first stator and second stator) arranged in series. This segmentation allows the creation of multiple shear areas within a compact volume, enabling increased torque generation without proportionally increasing device size. Each rotor-stator pair contributes to the overall torque output, achieving multiplicative torque enhancement within a constrained envelope.
Solution Approach 2:
The invention transitions from a single-plane shear area to a multi-plane three-dimensional arrangement of rotors and stators. By stacking multiple rotor-stator assemblies along the axial direction, the device creates multiple shear areas in series, effectively utilizing the third dimension (axial length) to increase torque capacity without expanding the radial footprint, thus maintaining compactness while enhancing force output.
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 allows for at least twice the resistance and torque generation compared to conventional devices, achieving higher torque output within the same size and cost constraints.
Implementation Method 1
A coil or permanent magnet can generate a magnetic field for directing a magnetic flux through desired regions of the magnetically controllable material to generate torque and/or resistance during operation of the field controllable device.
Implementation Method 2
In the case of MR fluids, the MR fluid exhibits a rheology change (e.g., an increase in viscosity, torque, resistance to shear, or the like) upon exposure to the magnetic field.
Data Source
AI summary
Integrated stator disk devices, systems, and methods for torque generation are provided. The resistive torque-generating device can include an integrated stator disk system including at least one metallic stator disk having a planar disk body, and at least one rotor disposed adjacent to the at least one metallic stator disk such that there are at least two shear areas formed by the at least one metallic stator disk and the at least one rotor; and magneto-rheological material disposed between portions of the at least one metallic stator disk and the at least one rotor. In some embodiments, the rotor(s) is/are a bent rotor(s), thereby providing for increased torque generation while fitting within tight space constraints.