Multi-Plate Coupling Assembly for Zero-Speed Output Control
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Solution Overview
Problem
Existing operating assemblies for power machines struggle to achieve continuous speed adjustment down to zero, particularly at low speeds, due to undesirable drag torque and power loss in multi-disc clutches, which limits their control and efficiency in applications like maritime propulsion and emergency services.
Innovation Solution
A dynamically controllable brake is integrated with the multi-disc clutch, allowing for simultaneous regulation of hydraulic pressure to compensate for drag torque and achieve desired output speeds, enabling continuous speed control from 0 to 100% of input speed through a compact unit with a control system that adjusts clutch and brake settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a multi-plate clutch is used for power transmission, then power transmission capability is improved, but drag torque increases at low speeds
Solution Approach 1:
The clutch pack is segmented into multiple friction plates and steel plates that can be independently pressed together, allowing progressive engagement and reduced drag torque at low speeds while maintaining power transmission capability when fully engaged
Solution Approach 2:
The hydraulic pressure applied to the clutch pack is dynamically adjusted based on operating conditions, enabling the system to optimize the balance between power transmission and drag torque by varying the contact pressure between plates
2Power
If hydraulic pressure is increased for full power transmission, then power transmission is improved, but speed control flexibility deteriorates
Solution Approach 1:
The hydraulic pressure to the clutch pack is made dynamically controllable through a pressure control valve, allowing continuous adjustment of the engagement state between plates, which enables flexible speed control from zero to full power transmission while maintaining adaptability to different operating conditions
3Speed
If clutch pressure is reduced for low-speed operation, then speed control is improved, but power transmission capability deteriorates
Solution Approach 1:
The clutch plates are engaged partially rather than fully, allowing the output speed to be controlled at values below the input speed while still transmitting a useful portion of the power, effectively enabling low-speed operation with maintained power transmission capability
4Speed
If a holding brake is added to lock the output shaft, then low-speed control is improved, but device complexity increases
Solution Approach 1:
The holding brake is integrated with the clutch assembly, sharing the same housing and mounting structure, which reduces the overall system complexity compared to a separate brake system while still providing the necessary low-speed locking capability
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 allows for precise control of output speed independently of engine speed, compensating for drag torque and enabling low-speed operations, such as emergency functions and slow travel, by dynamically adjusting the braking torque and clutch pressure, thus enhancing operational flexibility and efficiency.
Implementation Method 1
multi-plate discs, directly or indirectly connected to a drive shaft, rotate relative to fixed plates on the housing... Full contact results in power transmission (speed x torque)
Implementation Method 2
These plate packs can be moved axially against spring force or other preload, for example by hydraulic force
Implementation Method 3
a holding brake is optionally used in the area of an output shaft unit or the output shaft itself to permanently lock the driven machine
Data Source
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AI summary
The present invention relates to an operating assembly for the mechanical connection of a power machine with a working machine, comprising a drive shaft unit and an output shaft unit which are connected by means of a dynamically controllable multi-plate clutch, and comprising a holding brake acting on the output shaft unit and a control unit, wherein the holding brake is a dynamically controllable brake.