Continuous speed joint with disengagement capability

Abstract

A continuous-velocity joint assembly comprises an input shaft and an output shaft. A continuous-velocity mechanism enables power transfer between the input and output shafts while allowing angular variation between the shafts. A separating assembly is also provided, comprising first and second sections that are capable of rotating relative to each other in a separated state and are unable to rotate relative to each other in a connected state. An actuator causes the separating assembly to switch between the separated and connected states, thereby transferring power between the input and output shafts in the connected state and preventing power transfer between them in the separated state. At least one bearing can support the first and second sections.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application is based on and claims priority of the preliminary US patent application No. 63 / 468,705, filed on May 24, 2023, which is incorporated herein in full for all purposes. AREA OF INVENTION

[0002] The present invention relates generally to joints with continuous velocity. BACKGROUND

[0003] Mechanisms for selectively engaging and disengaging drive axles from the wheels of a vehicle are known. For example, basic concepts can include mechanisms where multiple drive axles in the powertrain are used on a continuous or full-time basis. For various reasons, powertrains in which drive axles can be engaged and disengaged as needed or desired have gained popularity in recent years. For example, known mechanisms allow a user to manually engage a vehicle's powertrain with the wheels, which typically requires the user to exit the vehicle to perform the manual intervention. Furthermore, automated systems are known in which a vehicle's control system automatically engages and disengages the powertrain from the wheels depending on driving conditions.However, such mechanisms often involve numerous, complex components and can therefore be complicated and costly to manufacture and maintain.

[0004] The present invention acknowledges and addresses considerations regarding designs and methods according to the prior art. SUMMARY OF THE INVENTION

[0005] One aspect of the present invention provides a continuous-velocity joint arrangement comprising an input shaft and an output shaft. A continuous-velocity mechanism enables the transfer of power between the input and output shafts while allowing angular variation between the shafts. A separating arrangement is also provided, comprising first and second sections that, in a separated state, are able to rotate relative to each other, but are unable to rotate relative to each other in a connected state. An actuator causes the separating arrangement to switch between the separated and connected states, thereby transferring power between the input and output shafts in the connected state and preventing power transfer between the input and output shafts in the separated state.At least one warehouse can insert the first section and the second section.

[0006] In some exemplary embodiments, the continuous-speed mechanism has an outer housing in which a shaft carrying several journals is received, the first and second sections being connected to the outer housing. At least a portion of the first section and at least a portion of the second section may be concentric with each other. The first section may have an axial extension integral with the outer housing, and the second section may be concentric with the axial extension. Alternatively, the first and second sections may be axially aligned with each other.

[0007] According to some exemplary embodiments, the disconnecting device can include a coupling mechanism that effects a selective coupling between the first and second sections. The coupling mechanism itself can include a sliding collar that is slidably movable on the second section between the disconnected and connected states. An axially movable connecting element can engage with the sliding collar. The coupling mechanism can further include a linear actuator that effects an axial movement of the connecting element and thus of the sliding collar.

[0008] In some exemplary embodiments, the linear actuator may comprise a screw-like actuator.

[0009] In some exemplary embodiments, the linear actuator may include a solenoid, such as a bistable solenoid.

[0010] Another aspect of the present invention provides a continuous-speed joint arrangement comprising an input shaft and an output shaft. A continuous-speed mechanism enables the transmission of power between the input and output shafts while allowing angular variation between the shafts. The continuous-speed mechanism has an outer housing containing a shaft carrying multiple journals. A separating arrangement is also provided, comprising first and second sections that, in a separated state, are able to rotate relative to each other, but, in a connected state, are unable to rotate relative to each other. The first section is integrally formed with the (e.g.,(entire or part of the) outer casing, wherein the disconnecting device comprises a coupling mechanism that effects selective coupling between the first and second sections. Additionally, an actuator causes the disconnecting arrangement to switch between the disconnected state and the connected state, whereby power is transferred between the input and output shafts in the connected state and power is not transferred between the input and output shafts in the disconnected state.

[0011] The accompanying drawings, which are included in and form part of this specification, illustrate one or more embodiments of the disclosure and, together with the description, serve to explain the principles of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] A complete and executable disclosure of the present invention, including its best mode, addressed to a person skilled in the art, is set forth in the specification, which refers to the accompanying drawings, in which: Fig. 1 a schematic representation of a half-wave arrangement according to the state of the art; Fig. 2 An enlarged view of one of the continuous velocity joints (CVJs) of the half-wave arrangement of Fig. 1 is; Fig. 3 a schematic view of a CVJ with separation capability according to an embodiment of the present invention; Fig. 4 is a schematic view of a CVJ with separation capability according to an embodiment of the present invention; Fig. 5 a schematic view of a CVJ with separation capability according to an embodiment of the present invention; Fig. 6 is a schematic view of a CVJ with separation capability according to an embodiment of the present invention; Fig. 7 is a schematic view of a CVJ with separation capability according to an embodiment of the present invention; Fig. 8 a view of the embodiment of Fig. 7, which further shows an actuator for axially moving the CVJ between connected and separated states; Fig. 9A and Fig. 9B the embodiment of the Fig. 7 show in connected or separate states; Fig. 10 a schematic view of a CVJ with separation capability according to an embodiment of the present invention; and Fig. 11 is a schematic view of a CVJ with separation capability according to an embodiment of the present invention.

[0013] The repeated use of reference numerals in this specification and the drawings is intended to represent identical or analogous features or elements of the invention as disclosed. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0014] Reference will now be made in detail to currently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is given to explain, not to limit, the invention. Indeed, it will be obvious to the person skilled in the art that modifications and variations can be made to the present invention without departing from its scope and spirit. For example, features illustrated or described as part of one embodiment can be used in another embodiment to give yet another embodiment. Thus, the present invention is intended to cover such modifications and variations as fall within the scope of the accompanying claims and their equivalents.

[0015] As background illustration Fig. 1. A prior art vehicle half-shaft assembly 10, which can be modified according to the principles of the present invention. The half-shaft 10 comprises first and second continuous velocity joints (CVJs) 12 and 14 near their respective ends. As is known, CVJs (also referred to as constant velocity joints) serve to transmit rotation from an input shaft to an output shaft when the angle between the shafts varies within a range. In this case, CVJ 12 is considered the "inner" CVJ because it is directly connected to a differential, such as via a stub shaft 16. CVJ 12 transmits torque to an intermediate shaft 18, which serves as the input for CVJ 14. CVJ 14 is considered the "outer" CVJ because it is connected to the driven wheel, such as via an output stub shaft 20.The CVJs 12 and 14 each have sleeves 22 and 24 extending between their outer casing (or simply ‘outer’) and the shaft 18 to allow angular movement, containing lubricant and protecting the interior of the CVJs from environmental contaminants.

[0016] With reference to Fig. In Figure 2, the inner CVJ 12 is typically designed as a "submerged CVJ," meaning that it accommodates some axial movement relative to the axle shaft 18. Submerged CVJs have a "tripod" 26 that interlocks with the axle shaft 18 and has three journals (such as the one shown at Figure 28) extending radially and spaced 120° apart. Each journal supports a barrel-shaped roller bearing that interacts with the outer CVJ 32. The shaft 16 extends from the outer 32, as shown. Accordingly, a rotation of the shaft 16 rotates the outer 32, which in turn rotates the tripod 26 and thus the axle shaft 18. The outer CVJ can also be a tripod CVJ or any other suitable type, but it will typically not be submerged.

[0017] Embodiments of the present invention provide a selective interruption of the power flow by means of a CVJ (which could be either an immersing or a non-immersing CVJ). This junction could be a standalone CVJ or a CVJ integrated into a half-shaft. (An example of an application of a standalone CVJ could be a driveshaft.) Some embodiments of the present invention achieve selective power separation by means of the CVJ using a two-part outer structure, wherein both parts can rotate independently about the same axis when separated, or can rotate together when connected. For example, the two parts can be concentric with each other.

[0018] The separation point between the two parts of the CVJ exterior could be located at a number of different points, some examples of which are shown in the drawing figures discussed below. A coupling mechanism is provided to selectively transfer power between the two. For example, the two parts could be selectively coupled using: • a transmission ring that is radially toothed on one side and selectively axially toothed on the other; • a transmission ring that is radially toothed on one side and selectively radially toothed on the other; • radially movable fins that are always in contact with one side and selectively in contact with the other; • any other suitable coupling mechanism as required or desired.

[0019] A suitable actuator is used to move the transmitting or radially movable components, such as: • Motor, rack and pinion. • Motor, leadscrew and fork. • Motor, half-spindle and fork. • Plunger-type solenoid and fork. • Ring-shaped solenoid and ring-shaped anchor. • Any other suitable linear or other actuator as required or desired.

[0020] In the case of a solenoid, a bistable solenoid is preferable. The solenoid could be made bistable using, for example, a permanent magnet locking system with a spring or a retractable pin-like mechanism. These bistable options have the advantage of remaining in the "failing to state" state when power is lost to the actuator. A retractable pin mechanism can also be used with a motor-based actuator.

[0021] In this context, it illustrates Fig. 3 A first embodiment of a CVJ 112 according to one aspect of the present invention. In this case, the CVJ 112 is integrated into a half-shaft assembly comprising a stub shaft 116 for connection to a differential and an axle shaft 118 extending to the outer CVJ. The CVJ 112 has an outer 132 with a first section 132a having a bell (or cup) shape with a closed end and an open end. The tripod 126 is received by the open end to be arranged in the bell-shaped section, as shown. The stub shaft 116 is attached to a second section 132b of the outer 132. As can be seen, the first section 132a is received in the second section 132b and is concentric with it. Suitable bearings, such as bearings 134 and 136, allow relative rotation between the first section 132a and the second section 132b when the coupling mechanism is disengaged.A flexible cuff 122 extends between the first section 132a and the axle shaft 118.

[0022] As shown, the coupling mechanism can connect sections 132a and 132b radially, as shown in 138, or axially, as shown in 140. Any suitable coupling mechanism can be used. Some examples are: pawl type, band coupling type, axial synchro type, clutch disc type, etc. When sections 132a and 132b are connected (i.e., when the coupling mechanism is engaged), they rotate together.

[0023] Fig. Figure 4 shows a second embodiment of a CVJ 212 according to one aspect of the present invention. Since the CVJ 212 is similar to the CVJ 112 in many respects, similar elements are identified by a reference numeral increased by one hundred compared to the reference numerals of the CVJ 112. In this case, however, the first section 232a has a greater axial width than the first section 132a, thus allowing a greater distance between the bearings 234 and 236. A wider bearing spacing may be desirable to achieve better system stiffness. It should be noted that in this case, the bearing 234 is located on a stepped section 242 of the first section 232a. The stepped section 242 is formed as an axial extension from the bell-shaped section of the first section 232a. A radial and / or axial coupling may be provided, as shown at 238 and 240.

[0024] Fig. Figure 5 shows a third embodiment of a CVJ 312 according to one aspect of the present invention. Since the CVJ 312 is similar to the CVJ 212 in many respects, similar elements are identified by a reference numeral increased by one hundred compared to the reference numerals of the CVJ 212. In this case, however, a further axial extension 344 is located within the stepped area 342 on which the bearing 334 is located. The extension 344, which may or may not have a smaller outer diameter than the area 342, provides another possible location for the coupling mechanism, as shown in Figure 346.

[0025] Fig. Figure 6 shows a fourth embodiment of a CVJ 412 according to one aspect of the present invention. Since the CVJ 412 is similar to the CVJ 312 in many respects, similar elements are identified by a reference numeral increased by one hundred compared to the reference numerals of the CVJ 312. In this case, however, the first section 432a has a longer axial extension 444, on which both the bearings 434 and 436 are located. Consequently, the second section 432b surrounds only the extension 444 and not the bell-shaped section of the first section 432a, in which the tripod 426 is located. This embodiment may be advantageous in applications where radial space is more limited. Furthermore, this embodiment provides another possible location for a radial and / or axial coupling mechanism, as shown in Figures 448a and 448b.

[0026] With reference to Fig. Figure 7 provides a further embodiment of the present invention, a CVJ 512, in which the separating device is provided on the inner “immersion side” of the CVJ for the purpose of packaging and environmental protection. In this respect, the CVJ seal can be transferred to the outside of the assembly. As shown, a translation ring (collar) 550 with axial keyways on its inner diameter is located on the outer diameter of the second section 532b, which has complementary keyways. No additional seal is required when the translation collar is moved inside the drive unit. ATF could also be used for lubricating the bearings and interfaces.

[0027] The support for both the fixed and offset sides of the arrangement is jointly provided by a ball bearing 534, here a sealed ball bearing with a sliding fit on an extension 542 of the second section 532b. Additionally, a thrust bearing 536 (here an NRB thrust bearing) can be arranged between the axially opposite surfaces of sections 532a and 532b. A wave spring 552 can be provided to eliminate any play in the arrangement that could cause noise from the thrust bearing or ball bearing when the assembly is disassembled.

[0028] With reference to Fig. 8 In this embodiment, the collar 550 is divided between a separate and a connected position ( Fig. 9A or 9B) is displaced, using a suitable connection 554 which is axially moved by a suitable linear actuator 556. In this case, the connection 554 is configured as a fork element with an intermediate elongated section 558. An arcuate section 560, which in this case is approximately semicircular, is located at the distal end of the elongated section 558. The arcuate section 560 is received in an annular channel 562 defined in the outer circumferential surface of the collar 550. Due to this configuration, the collar 550 can rotate with one or both of the input and output shafts (depending on whether it is in the disconnected or connected state), while the connection 554 remains rotatably fixed. However, the axial reciprocating movement of the connection 554 by the actuator 556 causes the collar 550 to shift between the connected and disconnected positions.

[0029] Instead of teeth on the first section 532a, the collar 550 may, for example, have axial pins or the like which engage in suitable openings on a flange 558 of the first section 532a.

[0030] Fig. Figure 10 shows another embodiment of a CVJ 612, in which a collar 650 has an axial or end-face wedge connection between the shaft stub 616 and the outer section 632a of the CVJ. A ball bearing 634 allows relative rotation in the disconnected state. A suitable actuator is used to effect the disconnection and connection.

[0031] Fig.Figure 11 shows another embodiment of a CVJ 712, in which a collar 750 is toothed with the outer surface of the outer section 732a of the CVJ. A ball bearing 734 allows relative rotation in the disconnected state and maintains the alignment in both the disconnected and connected states. A suitable actuator is used to effect the disconnection and connection.

[0032] Although one or more preferred embodiments of the invention are described above, the person skilled in the art should recognize that various modifications and variations can be made to the present invention without deviating from its scope and spirit. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 468,705

[0001]

Claims

[1] Continuous velocity joint arrangement comprising: an input wave and an output wave; a continuous-speed mechanism that allows power transfer between the input and output waves while enabling angular variation between the waves; a separating arrangement comprising first and second sections which, in a separated state, are able to rotate relative to each other, and, in a connected state, are unable to rotate relative to each other; and an actuator that causes the separating arrangement to switch between the separated state and the connected state, whereby power is transferred between the input and output waves in the connected state, and power is not transferred between the input and output waves in the disconnected state. [2] Continuous velocity joint arrangement according to claim 1, wherein the continuous velocity mechanism has an outer housing in which a shaft carrying several pins is received, the first and second sections being connected to the outer housing. [3] Joint arrangement with continuous velocity according to claim 2, wherein at least a part of the first section and at least a part of the second section are concentric to each other. [4] Joint arrangement with continuous speed according to claim 3, wherein the first section has an axial extension integral with the outer housing and the second section is concentric to the axial extension. [5] Joint arrangement with continuous velocity according to claim 2, wherein the first and the second section are axially aligned to each other. [6] Joint arrangement with continuous speed according to claim 1, wherein the separating device comprises a coupling mechanism that effects a selective coupling between the first and the second section. [7] Joint arrangement with continuous speed according to claim 1, wherein the coupling mechanism comprises a movable collar which is slidably movable on the second section between the separated state and the connected state. [8] Joint arrangement with continuous speed according to claim 6, wherein the coupling mechanism comprises an axially movable connecting device which engages with the movable collar. [9] Joint arrangement with continuous speed according to claim 7, wherein the coupling mechanism comprises a linear actuator that causes axial movement of the connecting device and thus of the movable collar. [10] Joint arrangement with continuous velocity according to claim 8, wherein the linear actuator comprises a screw-like actuator. [11] Joint arrangement with continuous velocity according to claim 8, wherein the linear actuator comprises a solenoid. [12] Continuous velocity joint arrangement according to claim 8, wherein the solenoid comprises a bistable solenoid. [13] Joint arrangement with continuous speed according to claim 1, wherein at least one bearing is arranged between the first section and the second section. [14] Continuous velocity joint arrangement comprising: an input wave and an output wave; a continuous-speed mechanism that enables the transfer of power between the input and output shafts while allowing angular variation between the shafts, wherein the continuous-speed mechanism has an outer housing in which a shaft carrying multiple pivots is accommodated; a separating arrangement comprising first and second sections which, in a separated state, are able to rotate relative to each other, and, in a connected state, are unable to rotate relative to each other, wherein the first section is integral with the outer housing, and wherein the separating device comprises a coupling mechanism which effects selective coupling between the first and second sections; and an actuator that causes the separating arrangement to switch between the separated state and the connected state, whereby power is transferred between the input and output waves in the connected state, and power is not transferred between the input and output waves in the disconnected state. [15] Joint arrangement with continuous velocity according to claim 14, wherein at least a part of the first section and at least a part of the second section are concentric to each other. [16] Continuous velocity joint arrangement according to claim 15, wherein the first section is designed as an axial extension which is integrally connected to a bell-shaped section of the outer housing, and wherein the second section is concentric to the axial extension. [17] Joint arrangement with continuous velocity according to claim 15, wherein the first and the second section are axially aligned to each other. [18] Continuous velocity joint arrangement according to claim 14, wherein the coupling mechanism comprises a movable collar which is slidably movable on the second section between the separated state and the connected state. [19] Joint arrangement with continuous speed according to claim 18, wherein the coupling mechanism comprises an axially movable connecting device which engages with the movable collar. [20] Joint arrangement with continuous speed according to claim 19, wherein the coupling mechanism comprises a linear actuator that causes an axial movement of the movable collar.

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