Segmented Clutch Structure for High Torque and Compact Volume
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Solution Overview
Problem
Conventional clutches face challenges in achieving high torque transmission capacity while maintaining a compact size, leading to increased operating force requirements and larger actuator sizes, and they often suffer from reduced durability due to heat concentration.
Innovation Solution
The clutch structure incorporates a hub, sleeve, clutch gear, friction rings, and a displacement conversion unit with friction members on specific diameter portions to distribute heat and reduce operating force, allowing for efficient torque transmission with a compact design and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the clutch size is increased to achieve higher torque transmission capacity, then the torque transmission capacity is improved, but the clutch volume increases
Solution Approach 1:
The clutch is divided into multiple friction rings (first friction ring, second friction ring) and multiple cones (clutch cone, middle cone) that work together in a segmented manner. Each friction ring contacts specific cone surfaces, creating multiple friction interfaces that collectively transmit torque. This segmentation allows the clutch to achieve high torque transmission capacity without requiring a single large friction interface, thus maintaining a compact overall volume.
2Power
If the operating force is increased to transmit larger torque, then the torque transmission capacity is improved, but the actuator size increases
Solution Approach 1:
The clutch structure segments the torque transmission function across multiple friction interfaces (first friction ring with clutch cone, second friction ring with middle cone, middle cone with first friction ring). This segmentation distributes the required operating force across multiple contact points, reducing the peak force required at any single interface and allowing for a more compact actuator design.
Solution Approach 2:
The clutch utilizes axial displacement of the sleeve to control engagement of multiple friction interfaces simultaneously. By moving the sleeve in the axial direction, the system engages/disengages multiple friction rings and cones in sequence or combination, effectively using axial motion to control torque transmission across multiple interfaces. This dimensional approach allows torque control without proportionally increasing operating force.
3Device complexity
If friction members are concentrated on one side, then the structure is simpler, but heat dissipation is insufficient reducing durability
Solution Approach 1:
Friction members are strategically placed on specific surfaces of the first friction ring, second friction ring, middle cone, and clutch cone based on local heat generation patterns and stress distribution. The friction members are positioned on inner and outer diameter portions of friction rings and cones where heat concentration occurs during engagement and disengagement. This localized placement optimizes heat dissipation and wear resistance at critical areas without requiring friction members on all surfaces, balancing structural simplicity with improved durability.
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 design enables high torque transmission with reduced operating force and actuator size, while effectively dispersing heat to enhance clutch durability and maintain a small, compact form.
Implementation Method 1
frictional force is generated between the clutch cone and the hub and consequently a torque is transferred
Implementation Method 2
the clutch structure improves the durability of the clutch by effectively dispersing heat generated by the clutch
Data Source
AI summary
A clutch structure of a transmission includes: a hub secured to a rotating shaft, a sleeve mounted on the hub so as to slide linearly, a clutch gear to rotate relative to the rotating shaft and integrally formed with a clutch cone, a first friction ring provided between the clutch gear and the hub to be pressed toward the clutch gear, a second friction ring having an inner surface to contact an outer surface of the clutch cone, and a middle cone having an inner surface to contact an outer surface of the second friction ring and an outer surface to contact an inner surface of the first friction ring. Each of the second friction ring and the middle cone is provided with a friction member on at least one of an inner diameter portion and an outer diameter portion each of the second friction ring and the middle cone.