Multi-Cone Clutch Structure for High Torque With Low Drag
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Solution Overview
Problem
Conventional clutches face challenges in achieving large torque transmission capacity while maintaining a compact volume and minimizing frictional force in a disengaged state to prevent drag and improve fuel efficiency.
Innovation Solution
A cone clutch design featuring a hub, sleeve, clutch ring, and multiple friction rings with inclined surfaces, allowing sequential contact and separation to manage torque transmission and reduce frictional force, utilizing oil flow to maintain a disengaged state with minimal drag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the friction area is increased to enhance torque transmission capacity, then the torque transmission capacity is improved, but the volume of the clutch increases
Solution Approach 1:
The patent transitions from a conventional multi-plate friction clutch design to a cone-shaped friction surface design. By changing the geometric dimensioning approach (using conical surfaces with gradual diameter decrease toward the hub), the friction area is expanded in a radial dimension rather than requiring additional axial plates, thereby increasing torque transmission capacity without proportionally increasing overall clutch volume.
Solution Approach 2:
The clutch employs curved conical friction surfaces instead of flat friction plates. The external diameter gradually decreases toward the hub, creating a tapered geometry that increases the friction area through curvature. This spherical/conical surface approach allows for greater friction contact area within a more compact volume compared to traditional planar friction surfaces.
2Power
If multiple parts are used to increase friction area, then the torque transmission capacity is improved, but the complexity of the structure increases
Solution Approach 1:
The patent integrates multiple friction surfaces into a unified cone-shaped structure. Instead of using separate friction plates stacked axially, the design merges the friction surfaces into a single conical geometry where the external diameter gradually decreases toward the hub. This consolidation reduces the number of discrete parts and simplifies the overall structure while maintaining adequate friction area for torque transmission.
Solution Approach 2:
The conical friction surface is segmented into multiple contact zones along the taper, with each zone contributing to the overall friction area. The gradual diameter decrease creates natural segmentation of friction contact regions, allowing torque transmission capacity to be increased through extended friction path length rather than through additional separate components.
3Loss of energy
If intervals between parts are secured to prevent drag in disengaged state, then fuel efficiency is improved, but the torque transmission capacity is reduced
Solution Approach 1:
The patent extracts the need for large axial intervals between friction surfaces by eliminating the stacked plate configuration. The conical design allows friction surfaces to be closer together axially while the radial taper provides sufficient separation between contact zones, preventing drag in the disengaged state without sacrificing torque transmission capacity during engagement.
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 cone clutch achieves high torque transmission capacity within a small volume, minimizing frictional force and drag in the disengaged state, thereby enhancing fuel efficiency by ensuring efficient power transmission and reducing unnecessary power consumption.
Implementation Method 1
a first friction ring (11) mounted between the clutch ring (9) and the hub (3) such that the rotation thereof is restrained relative to the hub (3), the first friction ring (11) being configured to be pressed toward the clutch ring (9) in an axial direction thereof to form frictional force with the clutch cone (7)
Data Source
AI summary
A cone clutch for a vehicle including a hub, a sleeve, and a clutch ring including a clutch cone, may further include a first friction ring for forming frictional force with the clutch cone, an internal middle cone, a second friction ring, an external middle cone, and a third friction ring, which are sequentially mounted to be brought into contact with each other. When the third friction ring is pressed by the sleeve and the third friction ring, the external middle cone, the second friction ring, the internal middle cone, the first friction ring, and the clutch cone are sequentially brought into close contact with each other, the distances from the hub in an axial direction gradually increase in the order of the first friction ring, the internal middle cone, the second friction ring, the external middle cone, and the third friction ring.