Wrap Spring Clutch for Accessory Power Management

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Solution Overview

Problem

Existing clutch mechanisms in driven accessories require electrical power to engage and disengage, which can lead to inefficiencies and reduced fuel efficiency in automotive applications, as they often operate continuously even when the accessory is not needed, draining vehicle batteries and reducing engine efficiency.

Innovation Solution

A clutched driven device with a wrap spring and actuator mechanism that selectively transmits rotary power between rotary clutch portions using a minimal amount of electrical power, allowing for pulsed operation of accessories like air conditioning compressors, reducing power consumption and extending battery life in hybrid or electric vehicles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a clutch mechanism is used to selectively operate the device, then fuel efficiency is improved by reducing continuous operation, but electrical power consumption increases due to the need for electrical power to engage and disengage the clutch

Engineering Contradiction:
Improvefuel efficiencyVSAvoidelectrical power consumption
Core Design Contradiction:
Loss of energyVSUse of energy by moving object

Solution Approach 1:

The patent replaces the conventional electrical clutch mechanism with a mechanical wrap spring-based clutch system. The wrap spring stores mechanical energy and engages/disengages the driven accessory through mechanical action alone, eliminating the need for electrical power to operate the clutch. This substitution directly addresses the contradiction by removing electrical power consumption while maintaining the ability to selectively operate the accessory for improved fuel efficiency.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The wrap spring mechanism is designed to automatically engage and disengage the driven accessory based on mechanical conditions without requiring external electrical control. The spring's inherent mechanical properties allow it to self-regulate the power transmission, making the system self-servicing and eliminating dependence on electrical power for clutch operation.

Inventive Principle:
Principle #25Self-service

2Reliability

If the accessory operates continuously to ensure availability, then reliability is improved, but fuel efficiency deteriorates due to unnecessary operation when the accessory is not needed

Engineering Contradiction:
Improveaccessory availabilityVSAvoidfuel efficiency
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent implements a dynamic clutch system using a wrap spring that can rapidly engage and disengage the driven accessory based on varying operational demands. This dynamic capability allows the system to switch between continuous operation (when reliability is critical) and selective operation (when fuel efficiency is prioritized), enabling flexible adaptation to different operating conditions without compromising either reliability or fuel efficiency.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The wrap spring mechanism enables periodic engagement and disengagement of the driven accessory, allowing it to operate only when needed rather than continuously. This periodic action pattern maintains accessory availability when required while eliminating unnecessary operation during periods when the accessory is not needed, thereby resolving the contradiction between reliability and fuel efficiency.

Inventive Principle:
Principle #19Periodic action

3Adaptability or versatility

If a conventional electrical clutch is used, then selective operation of the accessory is achieved, but device complexity increases due to additional electrical components and control systems

Engineering Contradiction:
Improveselective operation capabilityVSAvoidclutch mechanism complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts and removes the electrical components from the clutch mechanism, retaining only the essential mechanical elements needed for selective operation. By taking out the electrical motor, sensors, and control electronics from the clutch system and replacing them with a purely mechanical wrap spring mechanism, the patent achieves selective operation capability while significantly reducing device complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The wrap spring mechanism serves multiple functions within a single integrated component: it stores energy, transmits torque, engages the clutch, and disengages the clutch. This multi-functionality eliminates the need for separate electrical motors, control systems, and sensing elements, achieving selective operation capability with a simple, universal mechanical component that reduces overall device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 enables efficient engagement and disengagement of accessories with reduced electrical power consumption, enhancing fuel efficiency and prolonging battery life by allowing for pulsed operation and variable displacement control, thereby optimizing accessory operation based on demand.

Implementation Method 1

a wrap spring having a first end, a second end and a plurality of helical coils directly connected to the first and second ends. At least a portion of the plurality of helical coils engages the clutch surface. The wrap spring is configured to selectively transmit rotary power between the first rotary clutch portion and the second rotary clutch portion

Methodology Applied
Scientific EffectElastic deformation: Elasticity

Implementation Method 2

The actuator is selectively operable for generating a drag force that is applied to the second end of the wrap spring

Methodology Applied
Scientific EffectFriction: Friction

Data Source

PatentUS9441680B2Clutched driven device and associated clutch mechanism
Publication Date: 2016.09.13 LITENS AUTOMOTIVE INC
  • US9441680B2 patent drawing
  • US9441680B2 patent drawing
  • US9441680B2 patent drawing

AI summary

A driven accessory comprising a first rotary clutch portion, a second rotary clutch portion, a wrap spring and an actuator. The actuator is selectively operable for generating a force that is applied to a second end of the wrap spring. The actuator includes an actuator input member that is rotatable about a rotary axis relative to the first rotary clutch portion. The actuator input member is axially movable along the rotary axis between a first position, in which the actuator input member is drivingly engaged to the first rotary clutch portion to cause the wrap spring to uncoil against a clutch surface on the first rotary clutch portion such that rotary power is transmitted between the first rotary clutch portion and the second rotary clutch portion, and a second position in which the actuator input member is disengaged from first rotary clutch portion.