MR Clutch Torque Control for Hybrid Drivetrain Power Split
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Solution Overview
Problem
Current hybrid power systems face challenges in precisely controlling power distribution to different drivetrain loads, leading to potential damage and inefficiencies, particularly in vehicles using a combination of internal combustion engines and electric motors.
Innovation Solution
The implementation of magnetorheological (MR) clutches to manage power transfer between mechanical power sources and loads, allowing for precise control of torque and power distribution through varying the viscosity of MR fluid using electromagnetic fields, enabling gradual engagement and disengagement of loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical clutches are used for power distribution, then the system structure is simple, but the control precision is insufficient and sudden shocks may occur
Solution Approach 1:
The patent replaces traditional mechanical clutches with magnetorheological (MR) clutches that use electromagnetic fields to control power distribution. The MR clutch utilizes the magnetorheological effect to vary fluid viscosity and control torque transfer, eliminating the need for complex mechanical engagement mechanisms while achieving precise, shock-free power distribution control.
Solution Approach 2:
The patent changes the physical parameter of the MR fluid (viscosity) through application of electromagnetic fields. By varying the current to the electromagnet, the viscosity of the MR fluid changes, which directly controls the torque transfer ratio between power sources and loads, enabling continuous and precise power distribution control without mechanical contact.
2Reliability
If traditional mechanical clutches are used, then the system is easier to manufacture, but sudden engagement causes shocks and potential damage
Solution Approach 1:
The MR clutch provides inherent shock cushioning by using the controllable viscosity of MR fluid to gradually transmit torque during engagement. The fluid acts as a cushion that can be dynamically adjusted to prevent sudden shocks and mechanical impacts, protecting components from damage while maintaining ease of system integration.
Solution Approach 2:
The patent replaces mechanical engagement mechanisms that cause sudden shocks with an electromagnetic-based MR clutch system. This substitution eliminates mechanical impact during engagement while maintaining manufacturing simplicity, as the MR clutch consists of basic components (electromagnet, MR fluid, plates) that are straightforward to assemble.
3Reliability
If MR clutches are used for precise power distribution, then component protection is improved, but the system weight increases
Solution Approach 1:
The MR clutch uses thin plates and flexible MR fluid layers instead of heavy mechanical components. The MR fluid itself acts as a flexible coupling medium that provides protection while adding minimal weight, compared to traditional mechanical clutches with heavy friction plates, springs, and actuators.
4Ease of operation
If conventional power distribution systems are used, then the system is simpler to operate, but power distribution control is imprecise
Solution Approach 1:
The patent incorporates feedback control where the controller monitors power distribution requirements and adjusts the electromagnetic field strength in the MR clutch accordingly. This feedback mechanism maintains ease of operation through automatic control while achieving precise power distribution, as the system self-regulates based on sensor inputs without requiring complex manual operation.
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
Ensures safe and efficient power distribution by preventing sudden shocks to components, allowing for lighter system designs and concurrent operation of multiple propulsion systems, with controlled power transfer and failure modes.
Implementation Method 1
a magnetorheological (MR) clutch may include an input member, an output member, an electromagnet, and a quantity of magnetorheological fluid configured to provide a magnetorheological coupling between the input member and the output member
Implementation Method 2
an electromagnet, and a quantity of magnetorheological fluid configured to provide a magnetorheological coupling between the input member and the output member
Data Source
AI summary
Systems and techniques for controlling a power distribution of a hybrid powertrain system using magnetorheological (MR) clutches. In embodiments, MR clutches may be used to control the power transfer from a mechanical power source to a plurality of loads. For example, mechanical power produced by a mechanical power source (e.g., an internal combustion engine (ICE)) may be transferred to each load of the plurality of loads using an MR clutch respectively connected to each load. In this example, the amount of mechanical power transferred from the mechanical power source to each of the loads of the plurality of loads may be controlled and/or managed using the MR clutch connected to each respective load. In embodiments, a load may be engaged or disengaged from the mechanical power source gradually, such as by ramping up or ramping down the amount of mechanical power transferred via the MR clutch to the load.