Methods and apparatus for controlling the engagement of gap-type electromagnetic couplings

Abstract

A control unit and method for operating a gap-type electromagnetic clutch or brake is provided which reduces audible chatter, screeching caused by belt slippage and related wear and tear on the driving and driven components. The operating winding of the clutch or brake is energized to cause the gap between an armature and rotor to close, energization of winding is then reduced to initially reduce the torque coupling between the armature and rotor and finally energization of the winding is gradually increased to full energization so as to provide a gradually increasing torque coupling between the armature and rotor.

I claim as my invention: 
     
       1. Apparatus for energizing the multiple-turn winding of an electromagnetic coupling having an armature and a rotor separated by an air gap, said apparatus comprising: first means for initially energizing said winding for a period of time sufficient to build magnetic flux between said armature and rotor and across said air gap so as to cause said armature and rotor to close the air gap between them;   second means for reducing the energization of said winding after termination by said first means of said initial energization so as to allow slippage between said armature and rotor; and   third means, operative after the reducing effected by said second means, for gradually increasing the energization of said winding so as to increase the coupling torque and decrease the slippage between said armature and said rotor.   
     
     
       2. Apparatus as set forth in claim 1 wherein said first means including means for applying a source voltage to said winding for a predetermined time so that winding excitation current increases to a relatively high level sufficient to move the armature across the air gap and into contact with said rotor. 
     
     
       3. Apparatus as set forth in claim 1 wherein said second means includes means for reducing the average excitation current through said winding to a predetermined level which holds the armature and rotor in contact but which produces approximately zero torque coupling between the armature and rotor. 
     
     
       4. Apparatus as set forth in claim 1 wherein after the initial energization of said winding by said first means, said second means controls the average current through said winding so as to reduce the energization of said winding. 
     
     
       5. Apparatus as set forth in claim 4 wherein said third means supplies said winding with an average current whose value increases in time from an initial value equal to the average current in said winding supplied by said second means to a final value equal to the steady-state rated current value for said winding. 
     
     
       6. Apparatus as set forth in claim 1 including a final current control element in series with said winding and constituting a part of said first, second and third means. 
     
     
       7. Apparatus as set forth in claim 6 wherein said control element is a switch held closed by said first means and pulse-width modulated opened and closed by said second and third means. 
     
     
       8. Apparatus as set forth in claim 1 wherein said first means is initiated into operation by means responsive to a command signal calling for engagement of the electromagnetic coupling. 
     
     
       9. Apparatus as set forth in claim 1 wherein said first means includes means for connecting a dc. voltage source in series with said winding for said period of time. 
     
     
       10. Apparatus as set forth in claim 9 wherein said connecting means is a final control element in series with said winding and dc. voltage source, said control element constituting a part of said first, second and third means and being operable to connect and disconnect said winding to said source. 
     
     
       11. Apparatus as set forth in claim 10 wherein said final control element includes a solid state switch which is held steadily conductive by said first means so as to conduct excitation current from said dc. voltage source through said winding. 
     
     
       12. Apparatus as set forth in claim 11 wherein said switch is pulse-width modulated opened and closed by said second and third means so as to control the average exciting current through said winding. 
     
     
       13. A control unit responsive to a command signal for causing an electromagnetic coupling to engage, said coupling having (a) first and second members normally separated by an air gap and rotatable relative to one another, said members being movable into engagement by closure of the gap,   (b) spring means for normally holding said members separated by said gap and disengaged, and   (c) a multiple-turn winding and magnetically permeable flux path means for producing, when the winding is excited, magnetic flux threading through said members and gap to attract said members into torque-transmitting engagement, said control unit comprising, in combination,   (1) means responsive to said command signal for exciting said winding to create an average m.m.f. in said flux path means sufficient to attract said members into touching contact by relative motion which closes said gap,   (2) means responsive to the termination of winding excitation by said means (1) for reducing the average m.m.f. in said flux path means to a level at which said members are retained in touching contact but with a sufficiently low force that the members may rotatively slip without transmitting from one to the other the full torque for which the coupling is rated, and     (3) means operative after said means (2) have acted for gradually increasing the average m.m.f. in said flux path upwardly from its reduced value to a predetermined value which causes said members to be magnetically attracted so as to produce rate torque transmission.     
     
     
       14. A control unit as set forth in claim 13 wherein said means (1) includes means for exciting said winding for a predetermined period of time. 
     
     
       15. A control unit as set forth in claim 13 including, a final control element in series connection with said winding and a dc. voltage source, said element forming a part of each of said means (1), (2) and (3) to control the excitation of said winding. 
     
     
       16. A control unit as set forth in claim 15 wherein said control element, as a part of said means (1), connects said winding steadily in series with said dc. voltage source. 
     
     
       17. Apparatus responsive to a command signal for energizing the multiple-turn winding of an electromagnetic coupling having an armature and a rotor separated by an air gap, said apparatus comprising: a current control element in series with said winding and a dc. voltage source to variably control excitation current through the winding,   first means responsive to the command signal for initially conditioning said control element so as to connect said winding steadily in series with said voltge source for a least a period of time sufficient to draw the armature into contact with said rotor; and   second means, responsive to the end of the energization of said winding controlled by said first means, for conditioning said control element, so as (a) to restrict the current through said winding to an average level less than that at the end of the energization of said winding controlled by said first means and (b) thereafter to smoothly increase the average current through said winding to a level which provides full torque coupling between said armature and rotor.   
     
     
       18. Apparatus as set forth in claim 17 wherein said initial conditioning by said first means is for a predetermined time duration sufficient to insure the attractive force developed between said armature and said rotor is sufficient to move the armature across the air gap and into contact with said rotor. 
     
     
       19. Apparatus as set forth in claim 17 wherein said second means (i) reduces the average current through said winding to a predetermined level which produces approximately zero torque coupling between said rotor and said armature and (ii) thereafter smoothly increases the average current through said winding rotor over a time period sufficient to cause reduction of slippage between said armature and rotor with alleviation of chatter and noise. 
     
     
       20. Apparatus as set forth in claim 17 wherein said current control means is a switch controlled by said first means to be steadily closed and controlled by said second means to be alternately opened and closed to a frequency and variable duty cycle which initially permits smooth slippage of the armature relative to the rotor. 
     
     
       21. A method for energizing a multiple-turn winding of an electromagnetic coupling, wherein the armature and rotor of the coupling are separated by an air gap when the coupling is disengaged, said method comprising the steps of: energizing said winding so as to cause said armature to move across said air gap and into contact with said rotor;   reducing the energization of said winding after said gap has been closed so as to initially reduce the torque coupling which would otherwise be created between said armature and said rotor; and   gradually increasing the energization of said winding to full energization so as to provide a gradually increasing torque coupling between said armature and said rotor, thereby to alleviate the audible noise generated by the physical engagement of the armature to the rotor.   
     
     
       22. A method for energizing a multiple-turn winding of an electromagnetic coupling as set forth in claim 23 wherein the energization of said winding is reduced and thereafter increased to full torque coupling by pulse-width modulating the energization of said winding. 
     
     
       23. A method for energizing a multiple-turn winding of an electromagnetic coupling as set forth in claim 23 wherein the energization of said winding is reduced, after closure of said air gap, to a level which maintains gap closure but creates approximately zero torque coupling. .Iadd. 
     
     
       24.  A circuit for controlling a solenoid clutch which includes an electromagnet and has an input side rotating member and an associated output side rotating member to be engaged with the input side rotating member, the input side rotating member and the output side rotating member being separated by a gap when the solenoid clutch is in the completely disengaged state, said circuit comprising: a first means for producing at least one command signal for commanding the start of the engagement of said solenoid clutch; and   a second means responsive to said command signal for providing an exciting current for said electromagnet whose level is changed in such a way that the width of the gap is first reduced to zero and then the slip rate of said solenoid clutch is gradually changed from 1 to 0. .Iaddend. .Iadd.25. A circuit for controlling a solenoid clutch as claimed in claim 24 wherein said second means has a driving circuit for controlling the level of said exciting current, and a circuit means responsive to said command signal for producing a control signal for controlling said driving circuit so as to obtain an exciting current whose level is changed in such a way that the width of the gap is first reduced to zero and then the slip rate of said solenoid clutch is gradually changed from 1 to 0. .Iaddend. .Iadd.26. A circuit for controlling a solenoid clutch as claimed in claim 25 wherein said first means includes a start switch which is operated at the time of starting the engaging operation of said solenoid clutch and said at least one command signal is produced in response to the operation of said start switch. .Iaddend. .Iadd.27. A circuit for controlling a solenoid clutch as claimed in claim 25 wherein said circuit means has a first pulse generator responsive to said command signal for generating a first pulse signal of a predetermined pulse width, a second pulse generator for generating a plurality of second pulse signals, and means responsive to said first and second pulse signals for obtaining said control signal where said control signal includes said first pulse signal followed by a plurality of third pulse signals whose duty cycles gradually change in time, whereby the width of the gap is reduced to zero by the exciting current flowing in correspondence with said first pulse signal and then the slip rate of said solenoid clutch changes from 1 to 0 in correspondence with said second   
     
     
        pulse signal. .Iaddend. .Iadd.28.  A circuit for controlling a solenoid clutch as claimed in claim 27 wherein the pulse width of said first pulse signal is set so that said first pulse signal terminates when the width of the gap has been reduced to zero. .Iaddend. .Iadd.29. A circuit for controlling a solenoid clutch as claimed in claim 28 wherein the duty cycle of said third pulse signal at the termination of said first pulse signal is set so as to supply said electromagnet with exciting energy of a level necessary and sufficient for maintaining the width of the gap at zero. .Iaddend. .Iadd.30. A circuit for controlling a solenoid clutch as claimed in claim 27 wherein said first pulse generator is a mono-stable multivibrator which is triggered by the application of said command signal. .Iaddend. .Iadd.31. A circuit for controlling a solenoid clutch as claimed in claim 27 wherein said second pulse generator has a triangular pulse generator for generating a triangular pulse, said means responsive to said first and second pulse signals including (1) an integrator for generating a comparison signal whose level varies with the passage of time at least after the termination of the first pulse signal and (2) a voltage comparator responsive to the triangular pulse and the comparison signal for comparing the level of the triangular pulse with that of the comparison signal. .Iaddend. .Iadd.32. A circuit for controlling a solenoid clutch as claimed in claim 25 wherein said second means has a first signal generator responsive to said command signal for generating a first signal of a predetermined pulse width, a second signal generator for generating a second signal whose level increases with the passage of time at least after the termination of the first signal and a selecting means for selecting the larger of the first and second signals as the control signal. .Iaddend.