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
Engineering 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
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.
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.
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
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.
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.
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
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.
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.
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
Implementation Method 2
The actuator is selectively operable for generating a drag force that is applied to the second end of the wrap spring
Data Source
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.


