Rotational Coupling Electromagnetic Actuator Design
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Solution Overview
Problem
Conventional rotational coupling devices in industrial applications face issues with high maintenance and failure rates due to fluid actuators, especially in extreme temperature environments, and electromagnetic actuators are not scalable for larger devices due to size and packaging difficulties.
Innovation Solution
A rotational coupling device with an electromagnetic actuator assembly featuring a field shell, pole structure, armature, and actuator discs with cam surfaces and balls, which allows for compact packaging and efficient torque transfer, eliminating the need for fluid conduits and improving performance in extreme temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluid actuators are used to engage and release the rotational coupling device, then the device can be engaged and released, but the device requires a network of fluid conduits and sealing which creates high costs and maintenance issues
Solution Approach 1:
The patent removes the fluid actuator system entirely from the rotational coupling device, extracting the problematic fluid conduits and sealing requirements. Instead, it implements a mechanical actuator system with actuator discs, cams, and springs that provides the engagement/release function without requiring external fluid supply infrastructure, thereby eliminating maintenance issues associated with fluid seals and conduits.
Solution Approach 2:
The patent replaces the fluid-based actuation system with a purely mechanical actuator system. The mechanical actuator uses actuator discs with cam surfaces, balls, and springs to provide the engagement and release functions previously achieved by fluid pressure, eliminating the need for fluid conduits, seals, and associated maintenance while improving reliability.
2Volume of moving object
If electromagnetic actuators are used in smaller coupling devices, then the actuators can be compact, but they are not scalable for larger industrial clutches due to size and packaging difficulties
Solution Approach 1:
The patent divides the actuator system into multiple actuator discs (first actuator disc and second actuator disc) that are axially spaced apart. Each disc can be independently actuated, allowing the system to scale to larger torque capacities by adding more discs or increasing the size of individual discs without requiring a complete redesign of the electromagnetic actuator, thus achieving scalability while maintaining compact packaging.
Solution Approach 2:
The patent arranges multiple actuator discs in the axial dimension rather than requiring radial expansion. By stacking actuator discs along the axial direction with cam surfaces oriented to engage balls in the radial direction, the design achieves scalability for larger industrial applications without increasing the radial footprint, solving the packaging difficulty while maintaining compactness.
3Temperature
If fluid actuators are used in extreme temperature environments, then the actuators can function, but they work poorly in environments with extreme temperature conditions
Solution Approach 1:
The patent replaces the fluid-based actuator with a mechanical actuator system consisting of actuator discs, cam surfaces, balls, and springs. This mechanical system is inherently more suitable for extreme temperature environments as it eliminates fluid seals and conduits that are prone to failure under thermal stress, thereby maintaining reliability across a wider temperature range without the performance degradation experienced by fluid actuators.
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 electromagnetic actuator design provides cost savings, reduces maintenance issues, and enhances performance in extreme temperatures while offering improved packaging and efficiency compared to conventional designs.
Implementation Method 1
Energization of the conductor causes engagement of the armature with the pole structure and transfer of torque to the pole structure
Data Source
AI summary
A rotational coupling device is provided having an improved actuator for compressing friction discs coupled to an input ring and an output hub disposed about a rotational axis. The actuator includes a pole structure and a field shell housing a conductor, each with aligned, axially extending, radially spaced inner and outer poles. An armature is coupled for rotation with the input ring, but axially movable relative thereto and axially aligned with an end wall of the pole structure extending between the inner and outer actuator poles. First and second axially spaced actuator discs are disposed radially between the pole structure and the output hub with the first actuator disc rotatably coupled to the pole structure. The discs define cam surfaces along which a plurality of balls move to expand and contract the actuator discs upon relative rotation of the actuator discs.