CLUTCH DEVICE WITH EDDY CURRENT BRAKE WITH REDUCED AIR GAP

Abstract

The invention comprises a clutch device having an actuating device, wherein the actuating device has an electrical eddy current brake. The eddy current brake has a brake stator with at least one coil and a brake rotor with a brake region, wherein the brake region has a first layer which is electrically conductive and which has a first lateral face and a second lateral face, the first lateral face facing toward the coil and the second lateral face facing away from the coil. The brake region has a second layer which is magnetic and which is connected to the second lateral face. The invention further comprises a corresponding production method.

Claims

1-10. (canceled)

11. A clutch device comprising an actuating device, wherein the actuating device includes an electrical eddy current brake, wherein the eddy current brake includes a brake stator with at least one coil and a brake rotor with a brake region, wherein the brake region includes a first layer which is electrically conductive and which includes a first lateral face and a second lateral face, the first lateral face facing toward the coil and the second lateral face facing away from the coil, wherein the brake region includes a second layer which is magnetic and which is connected to the second lateral face.

12. A clutch device as recited in claim 21, wherein the brake region is at least partially cylindrical and the second layer is made of a ring-shaped material.

13. A clutch device as recited in claim 22, wherein the second layer is attached to the second lateral face by means of a press fit.

14. A clutch device as recited in claim 23, wherein the second layer is located radially outside of the first layer, and the brake stator comprises an internal stator which contains the coil.

15. A clutch device as recited in claim 25, wherein there is a minimal air gap present between the internal stator and the first layer, which is smaller than a minimal air gap between the second layer and a stator component adjacent to the second layer.

16. A clutch device as recited in claim 25, wherein an extension of the second layer is greater in the axial direction than in the radial direction.

17. A clutch device as recited in claim 26, wherein the second layer is thicker than the first layer.

18. A method for producing a clutch device comprising an actuating device, wherein the actuating device includes an electrical eddy current brake, wherein a brake stator with at least one coil and a brake rotor with a brake region are built into the eddy current brake, wherein the brake region is designed with a first layer which is electrically conductive and which includes a first lateral face and a second lateral face, the first lateral face being positioned facing toward the coil and the second lateral face being positioned facing away from the coil, characterized in that the brake region is designed with a second layer which is magnetic and which is connected to the second lateral face.

19. A method as recited in claim 28, wherein the second layer is attached to the second lateral face by means of a pressing process.

20. A method as recited in claim 29, wherein the second layer is pre-shaped in a ring form and the pressing process includes pressing the ring-type pre-shaped second layer onto a cylindrical wall region of the brake rotor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:

[0048] FIG. 1 is a schematic diagram of a clutch device according to the invention with a current eddy brake;

[0049] FIG. 2 is a perspective sectional view of the eddy current brake according to the prior art;

[0050] FIG. 3a is a sectional view of an eddy current brake according to the invention; and,

[0051] FIG. 3b is a sectional view along A-A of the eddy current brake according to the invention from FIG. 3.

DETAILED DESCRIPTION

[0052] At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements. It is to be understood that the claims are not limited to the disclosed aspects.

[0053] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the claims.

[0054] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.

[0055] It should be appreciated that the term substantially is synonymous with terms such as nearly, very nearly, about, approximately, around, bordering on, close to, essentially, in the neighborhood of, in the vicinity of, etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term proximate is synonymous with terms such as nearby, close, adjacent, neighboring, immediate, adjoining, etc., and such terms may be used interchangeably as appearing in the specification and claims. The term approximately is intended to mean values within ten percent of the specified value.

[0056] FIG. 1 shows a clutch device 102 according to the invention with eddy current brake 300. The clutch device 102 has an actuating device 204, which in turn has an eddy current brake 300. The eddy current brake 300 has a brake stator 303 having at least one coil 320 and a brake rotor 302 having a brake region 323. The brake region 323 has a first layer 324, which is electrically conductive and which has a first lateral face 324.1 and a second lateral face 324.2. The first lateral face 324.1 faces toward the coil 320 and the second lateral face 324.2 faces away from the coil 320. The brake region 323 has a second layer 325, which is magnetic and which is connected to the second lateral face 324.2.

[0057] During operation of the clutch device 102, by activating the eddy current brake 300, i.e., by applying current to the coil 320, a magnetic field is generated which produces eddy currents in the first layer 324. Through the second layer 325, the magnetic circuit (dashed line) closes in the second layer 325 and thus already in the brake rotor 302.

[0058] This avoids, in particular, the magnetic field from having to pass through yet another air gap, for example to an outer stator. Thus, the distance from the external stator or some other component in the vicinity of the brake rotor 302 can be enlarged and therefore the operational reliability increased. Furthermore, the brake rotor 302 gains heat capacity, which guards better against overheating, and efficiency is achieved due to the smaller air gap distance of the magnetic circuit.

[0059] FIG. 2 shows a perspective sectional view of the eddy current brake 300 according to the prior art. It has a brake stator 303 and a brake rotor 302. The brake stator 303 has an internal stator 304 and an external stator 306. At this point we refer to FIG. 4 of German patent application 10 2013 223 044.3, whose reference labels continue to be used and which shows the internal stator 304 in greater detail. The internal stator 304 has a first claw pole 308 having a disk segment 310 and pole claws, such as 312. The internal stator 304 has a second claw pole 314 having a disk segment 316 and pole claws, such as 318. The internal stator 304 has a central coil 320. The pole claws 312 of the first claw pole 308 are located on the radially outer side of the disk segment 310. The pole claws 312 of the first claw pole 308 are each angled at about 90 to the disk segment 310, and each have a free end tapering from wide to narrow. The pole claws 312 of the first claw pole 308 are distributed around the disk segment 310 in the circumferential direction. There are gaps between the pole claws 312 of the first claw pole 308. The pole claws 318 of the second claw pole 314 are located on the radially outer side of the disk segment 316. The pole claws 318 of the second claw pole 314 are each angled at about 90 to the disk segment 316, and each have a free end tapering from wide to narrow. The pole claws 318 of the second claw pole 314 are distributed around the disk segment 316 in the circumferential direction. There are gaps between the pole claws 318 of the second claw pole 314. The first claw pole 308 with its disk segment 310 and the second claw pole 314 with its disk segment 316 are positioned on both sides of the central coil 320. The pole claws 312 of the first claw pole 308 and the pole claws 318 of the second claw pole 314 surround and grip the central coil 320 radially on the outer side. The free ends of the pole claws 312 of the first claw pole 308 and the free ends of the pole claws 318 of the second claw pole 314 face toward one another. The pole claws 312 of the first claw pole 308 and the pole claws 318 of the second claw pole 314 mesh alternately with one another. The first claw pole 308 and the second claw pole 314 surround and grip the central coil 320 radially on the inside. The brake rotor 302 has a cup-like shape with a floor section 322 and a brake region with wall section and first layer 324. The brake rotor 302 is positioned with its floor section 322 on the second claw pole 314 and with its wall section positioned with the first layer 324 radially on the outer side of the internal stator 304. The external stator 306 is of coil-free design, and has a thin, flat ring-shaped form. The external stator 306 is magnetically permeable. The external stator 306 is positioned radially on the outer side of the brake rotor 302. The internal stator 304 and the external stator 306 are firmly connected to a supporting part 326. The supporting part 326 has a flange section and a hub section. The supporting part 326 and the external stator 306 form a housing-like receptacle for the internal stator 304 and the brake rotor 302. The first claw pole 308 is located on the flange section of the supporting part 326. The hub section of the supporting part 326 protrudes through a central cutout in the internal stator 304. The brake rotor 302 is supported rotatingly on the hub section of the supporting part 326 with the help of a bearing 328.

[0060] An eddy current brake 300 of this type has an air gap between the external stator 306 and the first layer 324, and the magnetic circuit must close in addition across this air gap.

[0061] FIG. 3a shows a sectional view along A-A of an eddy current brake 300 according to the invention, and FIG. 3b shows a sectional view of the eddy current brake according to the invention from FIG. 3. This eddy current brake builds on FIG. 1 and FIG. 2. In contrast to the eddy current brake 300 from FIG. 2, the brake rotor 302 has a second layer 325 in the brake region 323, i.e., here in the wall section having the first layer 324, and an external stator 306 is not absolutely necessary. In other respects it has preferably the same features as the eddy current brake 300 from FIG. 2 and FIG. 1. Furthermore, the brake region 323 is at least partially cylindrical and the second layer 325 is made of a ring-shaped material. The second layer 325 is attached to the second lateral face 324.2 by means of a press fit. The second layer 324.2 is located radially outside of the first layer 324.1, and the brake stator 303 has an internal stator 304 which contains the coil 320. There is a minimal air gap present between the internal stator 304 and the first layer 324, which is smaller than a minimal air gap between the second layer 325 and a stator component adjacent to the second layer 325. The extension of the second layer 325 is greater in the axial direction than in the radial direction. The second layer 325 is thicker than the first layer 324.

[0062] During operation of the clutch device, the magnetic circuit runs along the indicated path from {circle around (1)} through {circle around (2)} to {circle around (3)}. From a pole claw 318 of the second claw pole 314 here it runs across the air gap between the internal stator 304 and the first layer 324 of the brake rotor 302. It penetrates the first layer 324 (see {circle around (1)}) and passes over into the second layer 325, where it runs tangentially divided in the direction of the two adjacent pole claws 312 of the first claw pole 308 (see {circle around (2)}) and back again through the first layer 324, the air gap between internal stator 304 and the first layer 324 (see {circle around (3)}) into the first claw pole 308.

[0063] Hence, the magnetic circuit now runs only across an air gap, instead ofas in FIG. 2also imperatively across the air gap between the external stator 306 and the brake rotor 302. The reliability is thus increased, and in addition also the efficiency, since it is possible to dispense with keeping the distance between an external stator or similar component small and since the thermal capacity is higher.

[0064] With this invention, a clutch device having an eddy current brake with a reduced air gap has been presented. In this case, the magnetic circuit is not closed via the external stator, as in the past, but via an additional layer (e.g., ring-shaped) which rotates together with the brake rotor (for example a brake disk). This layer is preferably of a material having the highest possible permeability, and is pressed directly onto the eddy current ring. This arrangement makes it possible to prevent a malfunction due to the rotor and the external stator touching. Because of the reduced air gap, the magnetic flux density in the air gap and thus the braking torque of the eddy current brake continue to be increased. In addition, this variant has the advantage that the thermal mass of the disk is increased, and thus the latter heats up less when generating the braking torque for starting the motor (e.g., in deceleration mode to couple the combustion engine).

[0065] It will be appreciated that various aspects of the disclosure above and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

REFERENCE LABELS

[0066] 102 clutch device [0067] 204 actuating device [0068] 300 eddy current brake [0069] 302 brake rotor [0070] 303 brake stator [0071] 304 internal stator [0072] 306 external stator [0073] 308 first claw pole [0074] 310 disk segment [0075] 312 pole claw [0076] 314 second claw pole [0077] 316 disk segment [0078] 318 pole claw [0079] 320 central coil [0080] 322 floor section [0081] 323 brake region [0082] 324 first layer [0083] 324.1 first lateral face [0084] 324.2 second lateral face [0085] 325 second layer [0086] 326 supporting part [0087] 328 bearing