Variable Output Planetary Gear Set Using Eddy Current Brake

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Solution Overview

Problem

Conventional planetary gear sets require a large number of components, leading to potential component failure, increased costs due to friction-based clutches, and complex hydraulic circuitry, which complicates achieving multiple speed transmissions efficiently.

Innovation Solution

A variable output planetary gear set utilizing an eddy current electromagnetic brake to selectively apply a braking force, reducing the need for clutches and torque converters, and minimizing hydraulic components by using a single planetary gear set with an eddy current brake to control rotation and torque transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional planetary gear sets use multiple clutches and friction-based devices to achieve multiple speed transmissions, then the transmission functionality is improved, but the number of components increases and reliability decreases

Engineering Contradiction:

Improvemultiple speed transmission capabilityVSAvoidcomponent failure risk

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces friction-based mechanical clutches with an electromagnetic brake system that uses magnetic fields to control the planetary gear set. The electromagnetic brake applies braking force to the ring gear through eddy currents, eliminating the need for multiple friction clutches while achieving multiple speed transmissions, thereby reducing component count and improving reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the complex hydraulic circuitry and friction-based clutch mechanisms from the transmission system. By using a single electromagnetic brake instead of multiple clutches and hydraulic components, the system achieves multiple speed transmissions with fewer parts, reducing potential failure points

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If conventional planetary gear sets use friction-based clutches to control components, then the transmission functionality is improved, but the device lifespan decreases due to wear

Engineering Contradiction:

Improvetransmission control capabilityVSAvoidtransmission lifespan

Core Design Contradiction:

Adaptability or versatilityVSDuration of action of stationary object

Solution Approach 1:

The patent substitutes friction-based mechanical clutches with an electromagnetic brake that uses magnetic fields and eddy currents to control the planetary gear set. This non-contact braking method eliminates wear on brake surfaces, allowing the transmission to maintain its control capability while significantly extending its operational lifespan without the degradation associated with friction wear

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If conventional planetary gear sets use hydraulic circuitry and related components to achieve multiple speeds, then the transmission functionality is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvemultiple speed capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent removes complex hydraulic circuitry and related components from the transmission system. By using a single electromagnetic brake with electrical control instead of multiple hydraulic clutches and associated fluid systems, the patent achieves multiple speed transmissions while significantly reducing manufacturing complexity and cost

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The electromagnetic brake serves multiple functions that previously required separate hydraulic clutches and circuitry. A single electromagnetic brake system with electrical control achieves the multiple speed transmission capability, eliminating the need for complex hydraulic systems and reducing manufacturing costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If conventional planetary gear sets use multiple clutches and friction devices to achieve multiple speeds, then the transmission functionality is improved, but the device complexity increases

Engineering Contradiction:

Improvemultiple speed transmission capabilityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts and removes multiple friction-based clutches, torque converters, and complex hydraulic circuitry from the transmission system. By using a single electromagnetic brake with electrical control, the patent achieves multiple speed transmissions with significantly fewer components, reducing device complexity while maintaining functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the complex mechanical and hydraulic clutch system with an electromagnetic brake controlled by electrical signals. This substitution eliminates the need for multiple mechanical clutches and hydraulic circuitry, achieving multiple speed transmissions with a simpler, more compact design

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 decreases the number of components, reduces the risk of component failure, minimizes friction, and simplifies the system by using an eddy current brake to achieve variable speed transmissions without clutches or torque converters, thereby enhancing reliability and reducing costs.

Implementation Method 1

A conductive surface that moves past a stationary magnet will have circular electric currents called eddy currents induced in it by the magnetic field, as described by Faraday's law of induction

Methodology Applied

Scientific EffectEddy current: Eddy Currents

Implementation Method 2

The drag force in the eddy current brake is an electromagnetic force between a magnet and a nearby conductive object in relative motion due to eddy currents induced in the conductor through electromagnetic induction

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

An eddy current brake is a device used to slow or stop a moving object by dissipating its kinetic energy as heat

Methodology Applied

Scientific EffectElectromagnetic braking: Eddy Current Damping

Data Source

PatentUS10054204B2Variable output planetary gear set with electromagnetic braking

Publication Date: 2018.08.21 HARPER RICHARD

AI summary

A variable output planetary gear set includes an input shaft, and input gear affixed to the input shaft so as to rotate with a rotation of the input shaft, a brake rotor, a rotor input gear affixed to the brake rotor, a planetary gear set, an output shaft cooperative with the planetary gear set, and an electromechanical brake cooperative with the brake rotor so as to selectively apply a braking force so as to slow a rotation of the rotor input gear. The electromechanical brake is, in particular, an eddy current brake. The planetary gear set includes a planetary input gear, a planetary carrier, plurality of planetary gears, a sun gear and a ring gear. The input gear is engaged with the planetary input gear. The ring gear is engaged with the rotor input gear.