Positive-Locking Clutch Backlash for Compact Hybrid Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing clutches for hybrid vehicles require large construction space and high power to selectively transmit torque from an electric motor to a drive axle, especially when opening and closing during driving, due to the need to prevent mutual separation of clutch elements under substantial torques.
Innovation Solution
A positive-locking clutch with a coupling element and a rotatable counterpart element featuring a backlash between their toothings, actuated by an electromagnetic actuator, allowing for easy engagement and disengagement with reduced axial friction forces, facilitated by a pretension device and controlled by a control device that adjusts rotation speeds for smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clutch is designed to prevent mutual separation of clutch elements under substantial torques during driving, then reliability is improved, but device complexity and power requirements increase
Solution Approach 1:
The clutch design allows dynamic adjustment of the coupling element's position relative to the counterpart element. During engagement, the coupling element can move axially to accommodate tooth-to-tooth positioning variations. The electromagnetic actuator provides dynamic control, enabling the clutch to adapt its engagement state based on operating conditions, thus maintaining reliability without requiring overly complex mechanical restraint mechanisms
Solution Approach 2:
The invention changes the engagement parameters by allowing controlled axial movement of the coupling element during the engagement process. This movement enables the toothings to find their correct meshing position dynamically. The electromagnetic actuator controls this movement, changing the position parameter to achieve reliable engagement while keeping the mechanism simple
2Device complexity
If an electromagnetic actuator is used to move the clutch between engaged and disengaged positions, then device complexity is reduced, but the ability to operate under substantial torques during driving becomes problematic
Solution Approach 1:
The electromagnetic actuator is designed to control the coupling element's axial movement dynamically. During engagement under torque, the actuator maintains the coupling element in the correct position by controlling its axial displacement. The system operates in different dynamic states: during engagement it controls the movement to overcome tooth positioning, during operation it holds the position against torque, and during disengagement it reverses the movement
Solution Approach 2:
The coupling element acts as an intermediary between the electromagnetic actuator and the counterpart element. The actuator moves the coupling element axially, and this movement is transferred to the toothing engagement. The coupling element mediates the force transmission, allowing the actuator to operate with lower force requirements while still achieving reliable engagement under torque conditions
3Reliability
If the coupling element is moved axially to engage toothings, then engagement is achieved, but axial friction forces increase making disengagement difficult
Solution Approach 1:
The system uses dynamic control of the coupling element's axial position. During engagement, the coupling element moves axially to mesh the toothings, overcoming positioning variations. During disengagement, the electromagnetic actuator reverses this axial movement. The dynamic nature of this movement allows the system to overcome static friction during engagement and reduce friction during disengagement by controlling the speed and direction of movement
Solution Approach 2:
The electromagnetic actuator applies a preliminary force in the disengagement direction before full disengagement occurs. By controlling the axial movement of the coupling element, the actuator prepares the toothings for separation by reducing the engagement force, thereby counteracting the friction forces that would otherwise prevent easy disengagement
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 enables a compact and efficient clutch that can easily open and close, even during driving, by utilizing a backlash between toothings to reduce the forces required for engagement and disengagement, thus minimizing power consumption and construction size.
Implementation Method 1
an electromagnetic actuator, wherein the coupling element can be moved by means of the electromagnetic actuator between a disengaged position and an engaged position
Data Source
AI summary
A positive-locking clutch for a motor vehicle comprises a coupling element with a toothing, a rotatable counterpart element with a counterpart toothing, and an electromagnetic actuator. The coupling element can be moved by means of the electromagnetic actuator between a disengaged position and an engaged position, and wherein the toothing of the coupling element is meshed with the counterpart toothing of the counterpart element in the engaged position. Even after the engaged position of the coupling element has been fully reached, a backlash is provided between the toothing of the coupling element and the counterpart toothing of the counterpart element.