Multi-Level Torque Clutch Segmentation
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Solution Overview
Problem
Traditional torque clutch assemblies face challenges in achieving effective high and low torque transmission values due to the torque sensitivity of friction plates, which limits the range of pressure variation that can be applied, making it difficult to maintain optimal clutch operation across different torque levels.
Innovation Solution
A multi-level torque clutch assembly is introduced, featuring a secondary backing plate and a second actuator that selectively switches between low and high torque states by controlling the movement of the secondary backing plate, allowing for the isolation of friction plates to change the number of plates transferring torque, thereby maintaining optimal pressure and achieving different torque transmission values without varying the pressure applied by the first actuator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the pressure applied by the clutch actuator is varied to achieve different torque transmission values, then the torque transmission capability is improved, but the clutch operation reliability deteriorates because friction plates are torque sensitive in only a very narrow range of applied pressure
Solution Approach 1:
The clutch pack is segmented into multiple friction plates (first friction plate and second friction plate) that can be selectively engaged or isolated. The secondary backing plate acts as a movable separator that divides the friction plates into different groups, allowing independent control of which plates are active for torque transmission. This segmentation enables the system to achieve different torque levels by varying the number of engaged plates rather than varying pressure on all plates.
Solution Approach 2:
The secondary backing plate is designed to be movable along the longitudinal axis, transitioning between a locked position (isolating friction plates) and an unlocked position (allowing all friction plates to engage). This dynamic reconfiguration capability allows the clutch assembly to adapt its torque transmission characteristics by changing the number of active friction plates, maintaining optimal pressure conditions for reliable operation across different torque requirements.
2Power
If the pressure applied by the clutch actuator is increased to achieve high torque transmission values, then the torque transmission capability is improved, but the calibration difficulty increases because it becomes difficult to maintain optimal pressure for both high and low torque transmission
Solution Approach 1:
The clutch pack is segmented into multiple friction plates (first friction plate and second friction plate) that can be selectively engaged or isolated. The secondary backing plate acts as a movable separator that divides the friction plates into different groups, allowing independent control of which plates are active for torque transmission. This segmentation enables the system to achieve different torque levels by varying the number of engaged plates rather than varying pressure on all plates.
Solution Approach 2:
The secondary backing plate is designed to be movable along the longitudinal axis, transitioning between a locked position (isolating friction plates) and an unlocked position (allowing all friction plates to engage). This dynamic reconfiguration capability allows the clutch assembly to adapt its torque transmission characteristics by changing the number of active friction plates, maintaining optimal pressure conditions for reliable operation across different torque requirements.
3Adaptability or versatility
If the number of friction plates is increased to accommodate large differences in torque levels, then the torque transmission range is improved, but the device complexity increases
Solution Approach 1:
The clutch pack is segmented into multiple friction plates (first friction plate and second friction plate) that can be selectively engaged or isolated. The secondary backing plate acts as a movable separator that divides the friction plates into different groups, allowing independent control of which plates are active for torque transmission. This segmentation enables the system to achieve different torque levels by varying the number of engaged plates rather than varying pressure on all plates.
Solution Approach 2:
The secondary backing plate is designed to be movable along the longitudinal axis, transitioning between a locked position (isolating friction plates) and an unlocked position (allowing all friction plates to engage). This dynamic reconfiguration capability allows the clutch assembly to adapt its torque transmission characteristics by changing the number of active friction plates, maintaining optimal pressure conditions for reliable operation across different torque requirements.
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 solution provides better clutch control and easier calibration, enabling effective high and low torque transmission values by selectively isolating friction plates, ensuring optimal pressure is maintained while accommodating large differences in torque levels.
Implementation Method 1
The clutch pack may include various combinations of friction plates that transfer torque between the clutch housing and the shaft when the friction plates are pressed together by a clutch actuator
Implementation Method 2
The first and second friction plates are moveable along the longitudinal axis relative to the clutch housing and the shaft. The second actuator controls the movement of the secondary backing plate to selectively switch the clutch pack between a low torque state and a high torque state
Data Source
AI summary
A clutch assembly is disclosed having a clutch housing and a shaft. A clutch pack selectively couples rotation of the clutch housing and the shaft. The clutch pack includes a primary backing plate, a reaction plate, first and second friction plates disposed between the backing plate and the reaction plate, and a secondary backing plate disposed between the first and second friction plates. A first actuator selectively applies pressure to the reaction plate to move the reaction plate toward the primary backing plate. A second actuator controls movement of the secondary backing plate to switch the clutch pack between a low torque state and a high torque state. In the low torque state, the secondary backing plate cannot move longitudinally toward the primary backing plate beyond a locked position. In the high torque state, the secondary backing plate can move beyond the locked position.