Electromagnetic Jaw Clutch Gap Control for Reliable Engagement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electromagnetic clutches in new-energy vehicles face issues with insufficient attraction force when the gap between the movable and fixed gear sleeves is too large, and potential friction damage when the gap is too small, leading to inefficiency and reliability problems.
Innovation Solution
An electromagnetic jaw clutch design featuring a movable gear sleeve and a fixed gear sleeve with a cushioning component, accurate positioning between the armatures, and contrate teeth for controlled engagement and disengagement, reducing friction and ensuring a preset gap for optimal attraction force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gap between the movable armature and the fixed armature is increased to prevent contact and friction damage, then the reliability is improved, but the electromagnetic attraction force becomes insufficient
Solution Approach 1:
A positioning block is introduced as an intermediary component between the movable armature and the fixed armature. The positioning block defines and maintains a predetermined gap distance, preventing direct contact while ensuring sufficient electromagnetic attraction force by controlling the gap within optimal ranges.
2Force
If the gap between the movable armature and the fixed armature is decreased to increase electromagnetic attraction force, then the force is improved, but the risk of contact and friction damage increases
Solution Approach 1:
The positioning block serves as a mediator that prevents direct contact between the armatures while maintaining an optimal gap for electromagnetic attraction. This intermediary structure ensures both sufficient force and prevention of friction damage simultaneously.
Solution Approach 2:
The gap distance between the movable armature and the fixed armature is changed from a variable parameter to a controlled parameter with predetermined optimal values. The positioning block ensures the gap remains within the range of 0.5-2mm during operation, optimizing both attraction force and reliability.
3Strength
If the armatures are allowed to contact for firm engagement, then the engagement strength is improved, but remanence prevents disengagement and friction causes damage
Solution Approach 1:
The positioning block acts as an intermediary that maintains a controlled gap between the armatures during engagement, preventing direct contact while ensuring firm engagement through the gear sleeve teeth. This eliminates remanence issues and friction damage while maintaining engagement strength.
Solution Approach 2:
The engagement mechanism is segmented into two independent functions: the gear sleeve teeth provide engagement strength through mechanical interlocking, while the positioning block maintains the armature gap to prevent contact. This segmentation allows each component to optimize its specific function without compromising the other.
4Stability of the object's composition
If the bearing load is increased to support the electromagnetic force, then the structural stability is improved, but the bearing wear and maintenance requirements increase
Solution Approach 1:
The positioning block introduces a predetermined gap that prevents the armatures from contacting during normal operation, thereby eliminating additional radial loads on the bearings. This maintains structural stability while preserving bearing durability by avoiding excessive loading.
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 provides a compact, easily operated clutch system with reduced noise and friction, ensuring sufficient attraction force and preventing remanence-induced disengagement, while minimizing axial load on bearings, thus enhancing the reliability and efficiency of power transmission in new-energy vehicles.
Implementation Method 1
when the solenoid is electrified, the movable armature is attracted to the fixed armature by an electromagnetic force
Implementation Method 2
when the solenoid is powered off, a spring force of the spring causes the movable gear sleeve and the fixed gear sleeve to be disengaged
Data Source
Figure 1~2
Figure 3~4
AI summary
The present disclosure relates to the technical field of clutches, and particularly relates to an electromagnetic jaw clutch. The electromagnetic jaw clutch includes a movable gear sleeve (5) and a fixed gear sleeve (12) that are in engagement transmission, a fixed armature (10) is nested to an outer side of the fixed gear sleeve (12), the fixed armature (10) and the fixed gear sleeve (12) have a gap therebetween, and have a fixed position, a solenoid (11) is provided inside the fixed armature (10), a movable armature (8) is rotatably nested to an outer side of the movable gear sleeve (5), the movable armature (8) is movable along with the movable gear sleeve (5) in an axial direction, and when the solenoid (11) is electrified, the solenoid (11) attracts the movable armature (8) to the fixed armature (10), to cause the movable gear sleeve (5) and the fixed gear sleeve (12) to be engaged. The present disclosure provides an electromagnetic clutching system that has a compact structure, has no auxiliary executing structure and can be conveniently operated, which can be applied to electrically driving systems of new-energy vehicles. The system controls the transmission and disconnection of power torque.