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Through rigorous testing and evaluation of our numerous designs, a final coupler design was chosen. The main portion of our design that clearly defines our coupler over existing couplers is our unique linkage system input device. Four steel linkages, 90 degrees apart, which are composed of three links each, are connected with simple pins that allow for rotation. The linkages are permanently attached on one side to the input/driving shaft, and are attached on the opposite side to a basic clutch pack assembly. One variable solenoid is attached to each middle link in all four linkages to provide the desired input forces. The sensors on the driving wheels determine the timing and the amount of force necessary for the solenoid to produce. Upon activation, the linkages will be compressed in unison and the mechanical advantage of the linkage system will transfer a compressive force to the clutch pack assembly, thus coupling the driving shaft and driven shaft together.
The initial resting angle of the linkages was determined to be 18 degrees with a minimal angle of 4.8 degrees during maximum compression. With these angles and the lengths of the links (3 inches for the two side links and 1 inch for the middle), the packaging limits were calculated to be 10.35 inches in outer diameter and 7.24 inches in length.
Using a coefficient of friction for the clutch plates of 0.12 and the initial angle of rotation, the full 1032 ft-lbs of torque can be transmitted, while not exceeding the current limitations of 25 to 30 amps. The coupler would fail in the off position and the engagement/disengagement times are both up to standards.
Therefore, all of the specifications desired by Visteon were met and in some cases exceeded.
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