Variable Geometry Lever Clutch Actuator Reduces Motor Current
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Solution Overview
Problem
Conventional clutch actuators for automated manual transmissions consume high current and reduce fuel efficiency due to increased load on the motor when operating the release bearing, leading to hydraulic losses.
Innovation Solution
A clutch actuator design that utilizes a small-capacity motor with a movable member and lever system, employing principles of levers and a ball screw to convert rotational force into linear movement, amplifying the rotating force by varying the point of application and incorporating a resilient member to enhance the lever's rotating force, thereby reducing motor current consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a motor is used to operate the release bearing in a conventional clutch actuator, then the clutch can be operated automatically, but the current consumption increases and fuel efficiency deteriorates due to the high load on the motor
Solution Approach 1:
The lever is designed with a movable point of application that dynamically changes position during operation. As the lever rotates about the pivoting point, the point of application moves along the lever, causing the length between the force point and point of application to shorten. This dynamic adjustment optimizes the lever arm length throughout the motion cycle, improving mechanical advantage and reducing motor load.
Solution Approach 2:
The invention changes the geometric parameters of the lever system during operation. Specifically, the length between the force point and point of application varies as the lever rotates, transforming the mechanical advantage parameter dynamically. This parameter change allows the system to maintain optimal force multiplication throughout the clutch engagement stroke, reducing the power required from the motor.
2Reliability
If the operation stroke of the release bearing is increased to operate the clutch, then the clutch engagement is more complete, but the load on the motor increases rapidly
Solution Approach 1:
The lever system dynamically adjusts its mechanical advantage during the operation stroke. As the release fork moves and the lever rotates, the point of application shifts position, continuously optimizing the lever arm configuration. This dynamic adaptation allows the system to maintain sufficient force for complete clutch engagement while minimizing peak motor load throughout the stroke.
Solution Approach 2:
The lever acts as an intermediary mechanism between the motor and the release fork. By introducing this lever with variable geometry, the system mediates the force transmission, transforming the motor's linear motion into rotational motion of the release fork while optimizing force distribution. The lever's changing arm lengths provide mechanical advantage that reduces the direct load on the motor.
3Reliability
If a large-capacity motor is used to overcome the operation load, then the clutch can be operated reliably, but the fuel efficiency improvement is reduced
Solution Approach 1:
The variable geometry lever system dynamically optimizes force transmission throughout the clutch operation cycle. By continuously adjusting the effective lever arm length as the mechanism moves, the system maintains high mechanical advantage without requiring excessive motor power, thereby improving fuel efficiency while ensuring reliable clutch operation.
Solution Approach 2:
The invention utilizes parameter changes in the lever geometry during operation. The length between the force point and point of application varies as the lever rotates, transforming the mechanical advantage parameter to match the instantaneous load requirements. This allows reliable clutch operation with a smaller motor, reducing energy losses and improving fuel efficiency.
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 design effectively operates a high load clutch with a small-capacity motor, improving fuel efficiency by reducing current consumption and hydraulic losses, while also allowing for modular application in double clutch transmissions.
Implementation Method 1
a shaft of the motor and the movable member may be connected by means of a ball screw such that a rotation of the motor is converted into a linear movement of the movable member
Implementation Method 2
a lever which has a pivoting point at one end thereof and to which a release fork is connected at an opposite end thereof to provide a point of application, the lever being configured such that a location of the point of application is varied such that the lever is rotated about the pivoting point when a force point is pushed by the movable member
Implementation Method 3
a resilient member is resiliently provided at an opposite end of the third length element to provide a resilient force pushing out the third length element in a direction where the lever is rotated during rotation of the lever
Implementation Method 4
As one surface of the movable member pushing the lever may be inclined, the lever may be rotated while the lever may be frictionally moved along the inclined surface of the movable member when the lever is pushed by the movable member
Data Source
AI summary
A clutch actuator for a vehicle includes a movable member connected to a power generating unit and configured to be linearly moved by power provided by the power generating unit, and a lever having a pivoting point at one end thereof and to which a release fork is connected at an opposite end thereof to provide a point of application, the lever being configured such that a location of the point of application is varied such that the lever is rotated about the pivoting point when a force point is pushed by the movable member and a length between the point of application and the force point is shortened when the lever is rotated about the pivoting point and a rotating force of the lever is improved as the release fork is moved toward the pivoting point.