Integrated Viscous Clutch with Stationary Journal Bracket
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Solution Overview
Problem
Conventional viscous clutches in automotive fan drive applications face challenges with component complexity, increased power consumption, and bearing loading issues due to the separation of rotational inputs and external electromagnet coils, leading to inefficiencies and potential wear.
Innovation Solution
A compact viscous clutch design featuring a stationary journal bracket with an axially extending mounting shaft that supports both the electromagnetic coil and bearing sets, allowing for efficient magnetic flux transfer and reduced overhung loads, eliminating the need for additional components like slip rings and promoting balanced bearing loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electromagnetic coil is mounted externally on the clutch housing, then the magnetic flux can be transmitted to rotating components, but the coil necessitates additional mounting components and increases device complexity
Solution Approach 1:
The electromagnetic coil is integrated directly into the clutch housing structure, merging two previously separate components (coil and housing) into a unified assembly. This eliminates the need for separate mounting brackets, fasteners, and alignment mechanisms, thereby reducing device complexity while maintaining magnetic flux transmission capability to the rotating components through the housing material.
2Speed
If the coil is mounted on a bearing to support rotational movement, then rotational capability is provided, but the bearing experiences overhung loads that reduce its lifespan
Solution Approach 1:
The electromagnetic coil is extracted from the bearing support function and instead integrated into the clutch housing structure. This separates the magnetic flux generation function from the rotational support function, allowing the bearing to operate without carrying the overhung loads generated by an externally mounted coil, thereby extending bearing life while maintaining rotational capability.
3Ease of manufacture
If the coil is positioned outside the clutch housing, then mounting is simplified, but magnetic losses increase and power consumption rises
Solution Approach 1:
The electromagnetic coil is merged with the clutch housing structure, positioning it at the optimal location for magnetic flux transmission. This integration reduces magnetic losses by minimizing the magnetic path length and improving coupling with the rotating components, thereby reducing power consumption despite the slightly more complex integration process into the housing.
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 design enhances packaging efficiency, reduces power consumption, and prolongs bearing life by minimizing magnetic losses and overhung loads, resulting in a more reliable and cost-effective cooling system solution.
Implementation Method 1
Magnetic flux from the stationary electromagnet coil 24 can be transmitted to rotating components of the clutch 10 without any wear components
Implementation Method 2
Viscous clutches employ relatively thick silicon oil (generally called shear fluid or viscous fluid) for the selective transmission of torque between two rotating components
Data Source
AI summary
A viscous clutch (30; 30′) includes a stationary journal bracket (32; 32′) defining a mounting shaft (32-1; 32-1′), an output member (34; 34′) rotatably supported on the mounting shaft about an axis (A), an input member (34; 34′) rotatably supported on the mounting shaft about the axis, and a working chamber (50; 50′) defined between the input member and the output member to selectively transmit torque there between when a shear fluid is present. The mounting shaft extends axially through the viscous clutch from a front face (62; 62′) of the viscous clutch to a rear face (56; 56′) of the viscous clutch, with the rear face defining a mounting surface for mounting the viscous clutch at a mounting location. The front and rear faces are located at opposite sides of the viscous clutch and face in opposite directions.