Synchronized Wedge Clutch Single Actuator Design
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Solution Overview
Problem
Existing wedge clutches require two actuators, increasing cost, complexity, size, and energy requirements while reducing robustness and reliability due to the need for dual actuation mechanisms.
Innovation Solution
A wedge clutch design utilizing a single actuator and spring-biased pins to achieve synchronization stages, where the pins are initially radially outward to transmit torque and then displaced radially inward as the wedge clutch plate circumferentially moves with respect to the hub, eliminating the need for dual actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If two actuators are used to achieve synchronization stages, then the clutch can perform both clamping and rotation enablement functions, but the cost, complexity, size, and energy requirements increase
Solution Approach 1:
The patent combines the functions of two separate actuators into a single actuator that controls both the clamping action and the rotation enablement through a unified mechanism. The single actuator moves the pin between different radial positions, and this single action simultaneously achieves both synchronization stages through the integrated design of the pin, spring, and wedge clutch plate interactions.
Solution Approach 2:
The single actuator serves multiple functions: it clamps the clutch plates together for torque transmission and simultaneously enables rotation by allowing the pin to move radially inward. The pin itself also becomes multi-functional, serving both as a torque transmission element when radially outward and as a rotation-enabling element when radially inward.
2Ease of operation
If two actuators are used to achieve synchronization stages, then the clutch can perform both clamping and rotation enablement functions, but the reliability and robustness decrease
Solution Approach 1:
By merging the functions of two actuators into one, the patent eliminates the reliability issues associated with having multiple actuators that could fail independently. The single actuator system reduces the number of potential failure points while the spring-biased pin mechanism provides passive reliability through mechanical spring force that maintains engagement without requiring active control.
3Ease of operation
If two actuators are used to achieve synchronization stages, then the clutch can perform both clamping and rotation enablement functions, but the energy requirements increase
Solution Approach 1:
The patent combines the energy-consuming actions of two actuators into a single actuator operation. The spring-biased pin mechanism further reduces energy requirements by using stored elastic energy in the spring to maintain the pin in the radially outward position, eliminating the need for continuous actuator power to maintain clamping pressure.
4Ease of operation
If two actuators are used to achieve synchronization stages, then the clutch can perform both clamping and rotation enablement functions, but the cost increases
Solution Approach 1:
By merging the functions of two actuators into one, the patent significantly reduces manufacturing costs. The simpler actuator system requires fewer components, less complex control electronics, and easier assembly. The spring-biased pin mechanism uses simple, inexpensive mechanical elements that are easy to manufacture and assemble.
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 simplifies the clutch mechanism, reduces energy requirements, and enhances reliability by using a single actuator and resilient elements, while maintaining robustness and efficiency in torque transmission.
Implementation Method 1
a resilient element disposed in the slot and urging the pin radially outward
Data Source
AI summary
A wedge clutch, including: an outer carrier; a first clutch plate non-rotatably connected to the outer carrier; a wedge clutch plate; a hub radially inward of the outer carrier; an engagement assembly including a pin partially disposed within the hub and in contact with the wedge clutch plate; and an actuator. For a first synchronization stage for closing the wedge clutch: the actuator is arranged to clamp the first clutch plate and the wedge clutch plate; and a first portion of the pin extending radially outward beyond an outer circumference of the hub is arranged to transmit torque between the hub and the carrier. For a second synchronization stage for closing the wedge clutch: the hub or the wedge clutch plate are arranged to circumferentially displace with respect to each other; and the wedge clutch plate is arranged to displace the pin radially inward.