Axle disconnecting device

Abstract

A disconnect unit allows one axle of a vehicle to be disconnected from a driveline. The disconnect unit is electronically controlled via an electromagnet. Certain types of disconnect units may be encapsulated within the gear reduction unit. Certain types of disconnect units include a stator holding an electromagnet, a support coupling rotationally fixed to an intermediate shaft, and a displaceable locking plate rotationally fixed to the support coupling. The locking plate is displaced into and out of engagement with the gear output based on an actuated state of the electromagnet.

Description

[0001] Cross-references to related applications

[0002] This patent application claims the benefit of U.S. Provisional Application No. 63 / 493,366, filed March 31, 2023, entitled “Wheel Axle Disconnection Device,” the disclosure of which is hereby incorporated by reference in its entirety. Background Technology

[0003] A reduction drive unit typically includes a drive motor, a shaft driven by the drive motor, and a reduction gear transmission driven by the shaft. The reduction gear drives the wheel hubs of a vehicle. Such reduction drive units are known in the art and are illustrated by U.S. Patents 3,686,978 and 3,737,000. Summary of the Invention

[0004] Several aspects of this disclosure relate to an axle disconnection unit for disconnecting a wheel hub from a drive motor. For example, the axle of the drive wheel hub can be disconnected from a reduction gear driven by the drive motor. Under certain conditions, the required power can be provided to the vehicle without all wheels. In this case, disconnecting one or more of the multiple wheels from the drive motor can save power and improve vehicle efficiency. In some implementations, the wheel can be disconnected from the drive motor by disconnecting the wheel axle from the drive motor.

[0005] According to certain aspects of this disclosure, the disconnect unit may be packaged together with a gear reduction unit. The gear reduction unit receives power from a drive motor and outputs power through an output gear. The gear reduction unit also includes an intermediate shaft coupled to the wheel axle to drive the wheel. The disconnect unit controls when the output gear is connected to the intermediate shaft. In some instances, the output gear, intermediate shaft, and disconnect unit are housed within the same housing.

[0006] According to certain aspects of this disclosure, the disconnecting unit has a first portion connected to an intermediate shaft and a second portion selectively connected to an output gear. The first portion is configured to drive the intermediate shaft when the first portion rotates. The second portion is axially movable relative to the first portion to selectively engage the output gear. The second portion is rotatably fixed (or non-rotatable) relative to the first portion. Therefore, when the second portion engages the output gear, the rotation of the output gear is transmitted to the first portion, and thus to the intermediate shaft. When the second portion disengages from the output gear, the rotation of the output gear is not transmitted to the intermediate shaft.

[0007] In some implementations, the movement of the second part is controlled using an electromagnet.

[0008] In some implementations, the second portion is biased to engage with the output gear. In other implementations, the second portion is biased to disengage from the output gear.

[0009] In certain implementations, the first portion of the disconnect unit includes a support coupling. In certain implementations, the second portion of the disconnect unit includes a locking plate.

[0010] Various additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based. BRIEF DESCRIPTION OF DRAWINGS

[0011] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate several aspects of the present disclosure. A brief description of each drawing is as follows:

[0012] Figure 1 is a schematic diagram of an example drive system including a drive motor, a disconnect unit configured in accordance with the principles of the present disclosure, and a vehicle wheel;

[0013] Figure 2 is a schematic diagram of an example drive system including a drive motor, a gear reduction unit including a disconnect unit configured in accordance with the principles of the present disclosure, and a vehicle wheel axle;

[0014] Figure 3 is an exploded view of an example implementation of the gear reduction unit of Figure 2 including an output gear, an intermediate shaft, and an example disconnect unit packaged within a housing;

[0015] Figure 4 is an axial cross-sectional view of components of the gear reduction unit of Figure 3 shown in a connected state;

[0016] Figure 5 is an axial cross-sectional view of components of the gear reduction unit of Figure 3 shown in a disconnected state;

[0017] Figure 6 is an exploded view of another example implementation of the gear reduction unit of Figure 2 including an output gear, an intermediate shaft, and an example disconnect unit packaged within a housing;

[0018] Figure 7 is an axial cross-sectional view of components of the gear reduction unit of Figure 6 shown in a connected state; and

[0019] Figure 8 is an axial cross-sectional view of components of the gear reduction unit of Figure 6 shown in a disconnected state. DETAILED DESCRIPTION

[0020] Reference will now be made in detail to the exemplary aspects of the present disclosure as illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0021] According to certain aspects of the present disclosure, the disconnect unit 101 is operatively disposed between the drive motor DM and the vehicle wheel W. In certain implementations, the disconnect unit 101 is indirectly connected to the drive motor (e.g., via a drive gear, a drive shaft, etc.). In certain implementations, the disconnect unit 101 is indirectly connected to the vehicle wheel (e.g., via a wheel axle, etc.). The disconnect unit 101 controls whether the drive motor DM provides power to the vehicle wheel W. The disconnect unit 101 is configured to transition between a connected state and a disconnected state. When in the connected state, the disconnect unit 101 connects the drive motor DM to the vehicle wheel W. When in the disconnected state, the disconnect unit 101 disengages the drive motor DM from the vehicle wheel W.

[0022] In certain implementations, the disconnect unit 101 includes an electromagnet 103 and a ferrous component 105. The ferrous component 105 is movable between a first position and a second position. When the ferrous component 105 is disposed in the first position, the disconnect unit 101 is configured to be in the connected state. When the ferrous component 105 is disposed in the second position, the disconnect unit is configured to be in the disconnected state. In certain instances, the ferrous component 105 is biased toward one of the first position and the second position. The electromagnet 103, when actuated, causes the ferrous component 105 to move against the bias toward the other of the first position and the second position. Thus, in some instances, actuating the electromagnet 103 transitions the disconnect unit 101 to the connected state. In other instances, actuating the electromagnet 103 transitions the disconnect unit 101 to the disconnected state.

[0023] According to certain aspects of the present disclosure, a disconnect unit 101 can be provided within a gear reduction unit 100. The gear reduction unit 100 includes a housing 102 in which an intermediate shaft 104 and a gear output 106 (e.g., a primary gear output) are provided. In the figures, the gear output 106 is not shown with teeth for convenience. However, it will be understood that the gear output 106 is a spur gear, a bevel gear, etc. having outer peripheral teeth (e.g., for meshing with a drive gear DG of a drive motor DM). An axle A of a vehicle wheel W can be coupled to the intermediate shaft 104 to rotate therewith. Torque from the drive motor DM can be supplied to the gear output 106 of the gear reduction unit 100. However, the gear output 106 is not directly rotationally locked to the intermediate shaft 104. For example, the gear output 106 can define a smooth interior passage through which the intermediate shaft 104 passes and / or the intermediate shaft 104 can define a smooth exterior that extends through the gear output 106. Connection and disconnection of the gear output 106 and the intermediate shaft 104 is controlled using the disconnect unit 101.

[0024] According to certain aspects of the present disclosure, a disconnect unit 101 is provided within a housing 102 of a gear reduction unit 100. The disconnect unit 101 controls whether the intermediate shaft 104 is operatively connected to the gear output 106. Thus, the disconnect unit 101 controls whether the drive motor DM is operatively connected to the axle A of the vehicle wheel W. The axle A can be connected to one or more vehicle wheels W.

[0025] In certain implementations, the disconnect unit 101 rotationally couples or decouples the intermediate shaft 104 and the gear reduction unit 100 by using an electromagnet 112. The electromagnet 112 is configured to generate a magnetic field when current is flowing through the electromagnet 112. When the current is no longer provided to the electromagnet 112, the electromagnet 112 stops generating the magnetic field. Generation of the magnetic field causes a ferrous component 105 of the disconnect unit 101 to move (e.g., a sliding movement) into engagement with the gear output 106 and out of engagement with the gear output. The ferrous component 105 is directly or indirectly rotationally locked to the intermediate shaft 104. Thus, when the ferrous component 105 is in engagement with the gear output 106, rotation of the gear output 106 is transmitted to the intermediate shaft 104 by the ferrous component 105.

[0026] Figures 3 to 5 A first example implementation of a disconnect unit 110 provided within a gear reduction unit 100 is shown. The first disconnect unit 110 is configured to maintain a disconnect between a drive motor and a vehicle wheel until an electromagnet is actuated. Figures 6 to 8 A second example implementation of a disconnect unit 160 provided within a gear reduction unit 100 is shown. The second disconnect unit 160 is configured to maintain a connection between a drive motor and a vehicle wheel unit until an electromagnet is actuated.

[0027] ReferenceFigures 3 to 8 In certain implementations, the disconnect unit 110, 160 includes a stator assembly 108, a lock plate 114, a support link 116. The intermediate shaft 104 extends through the lock plate 114, the support link 116, and the stator assembly 108. The stator assembly 108 is disposed within the housing 102 of the gear reduction unit 100. The stator assembly 108 is rotationally stationary relative to the housing 102. The intermediate shaft 104 is configured to rotate relative to the stator 108. In certain implementations, the electromagnet 112 is mounted to the stator 108.

[0028] In certain implementations, the lock plate 114 includes one or more dog teeth 120 or other engagement members that extend axially away from the lock plate 114 toward the gear output 106. The gear output 106 also includes dog teeth 140 or other engagement members that extend axially toward the lock plate 114. Engagement between the dog teeth 120 (or other engagement members of the lock plate 114) and the dog teeth 140 (or other engagement members of the gear output 106) rotationally locks the lock plate 114 and the gear output 106 for integral rotation. Other meshing configurations are possible.

[0029] The lock plate 114 is indirectly rotationally coupled to the intermediate shaft 104 such that rotation of the lock plate 114 is translated to rotation of the intermediate shaft 104. Thus, sliding the lock plate 114 into engagement with the gear output 106 transmits rotation of the gear output 106 to rotation of the intermediate shaft 104. Sliding the lock plate 114 out of engagement with the gear output 106 rotationally decouples the intermediate shaft 104 from the gear output 106.

[0030] In certain implementations, the support link 116 is rotationally locked to the intermediate shaft 104. For example, the support link 116 can define splines (not shown) or other engagement features at an interior passage 132 of the support link 116 to mesh with engagement features at an exterior of the intermediate shaft 104. In certain implementations, the support link 116 is also rotationally locked to the lock plate 114. For example, the support link 116 can define a catch surface 134 that interfaces with a retention member 122 of the lock plate 114. In certain instances, the retention member 122 protrudes radially outward from a perimeter of the lock plate 114, and the catch surface 134 is formed at an inward-facing groove of the support link 116.

[0031] In some implementations, the support coupling 116 is axially fixed relative to the stator 108. In other implementations, the support coupling 116 is axially floating relative to the stator 108. The support coupling 116 defines a recess 130 in which the lock plate 114 is disposed. The lock plate 114 is axially movable relative to the support coupling 116 between a first position and a second position. The lock plate 114, when disposed in the first position, engages the gear output 106. The lock plate 114, when disposed in the second position, does not engage the gear output 106 (e.g., is spaced apart from the gear output). In certain implementations, the lock plate 114 is rotationally locked to the support coupling 116 in both axial positions.

[0032] The pin 124 extends from the lock plate 114 away from the gear output 106 toward the stator 108. In certain implementations, the pin 124 moves axially as a unit with the lock plate 114. In certain implementations, the pin 124 passes through a guide hole 136 defined through the support coupling 116. In certain instances, the guide hole 136 extends through the support coupling 116 parallel to the passage 132. The pin 124 slides along the guide hole 136 as the lock plate 114 moves between the first position and the second position.

[0033] The armature 125 is mounted to the support coupling 116 at a location spaced apart from the lock plate recess 130. For example, the armature can extend around a mounting region of the support coupling 116. The armature 125 is configured for limited axial movement relative to the support coupling 116. For example, the support coupling 116 can include or carry a stop member 135 that blocks movement of the armature 125 away from the support coupling 116. The pin 124 of the lock plate 114 is long enough to extend through the support coupling 116 and contact the armature 125. In certain implementations, the armature 125 includes or carries a ferrous material. For example, a portion of the armature 125 that is axially aligned with the electromagnet can be formed of a ferrous material.

[0034] Reference is now made to Figures 3 to 5The first example disconnect unit 110 has the gear output 106 disconnected from the intermediate shaft 104 in the absence of an electromagnetic force from the electromagnet 112. A biasing element 118 (e.g., a spring) is disposed between the gear output 106 and the locking plate 114 to bias the locking plate 114 away from the gear output 106. An armature 125 is disposed on the opposite side of the stator 108 from the support link 116. When current flows through the electromagnet 112, the ferrous metal is attracted to the electromagnet 112, thereby pulling the armature 125 toward the stator 108. As the armature 125 moves toward the stator 108, the armature 125 engages the pin 124 of the locking plate 114, thereby pushing the locking plate 114 against the bias of the biasing element 118 and into engagement with the gear output 106. To disconnect the gear output 106 from the intermediate shaft 104 (and thus disconnect the drive motor from the axle), the current to the electromagnet 112 is stopped. When the electromagnet 112 is de-energized, the force of the biasing element 118 is sufficient to push the locking plate 114 out of engagement with the gear output 106.

[0035] Referring now to the drawings Figures 6 to 8 The second example disconnect unit 160 has the gear output 106 connected to the intermediate shaft 104 in the absence of an electromagnetic force from the electromagnet 112. A biasing element 118 (e.g., a spring) is disposed between the locking plate 114 and the support link 116 to bias the locking plate 114 toward the gear output 106. The armature 125 is disposed on the same side of the stator 108 as the support link 116. When current flows through the electromagnet 112, the ferrous metal is attracted to the electromagnet 112, thereby pulling the armature 125 toward the stator 108 and away from the gear output 106.

[0036] In certain implementations, the pin 124 is axially locked to both the locking plate 114 and the armature 125. Thus, as the armature 125 moves toward the stator 108, the armature 125 pulls the locking plate 114 via the pin 124 out of engagement with the gear output 106. The support link 116 allows sufficient axial movement of the armature 125 to pull the locking plate 114 out of engagement with the gear output 106. To again connect the gear output 106 to the intermediate shaft 104 (and thus connect the drive motor to the axle), the current to the electromagnet 112 is stopped. When the electromagnet 112 is de-energized, the force of the biasing element 118 is sufficient to push the locking plate 114 into engagement with the gear output 106.

[0037] Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts can readily occur to one skilled in the art. However, such modifications and equivalents are intended to fall within the scope of the claims that follow.

Claims

1. A gear reduction unit, comprising: Intermediate shaft, extending along the axis; The stator is arranged around the intermediate axis; Gear output, mounted around the intermediate shaft; A support connector is mounted on the intermediate shaft, the support connector is axially fixed to the intermediate shaft, and the support connector is configured to drive the intermediate shaft when the support connector rotates; A locking plate is axially mounted between the support connector and the gear output. The locking plate is movable relative to the support connector along the axis between a connected position and a disconnected position. The locking plate is configured to engage the gear output when in the connected position and to be spaced apart from the gear output when in the disconnected position. An armature, mounted to the support coupling, the armature being configured for limited movement relative to the support coupling along the axis, the armature being connected to the locking plate to move integrally with the locking plate between the connected position and the disconnected position, and the armature comprising ferrous metal; as well as An electromagnet is disposed at the stator. When the electromagnet is activated, it attracts the ferrous metal to move the armature along a first direction.

2. The gear reduction unit according to claim 1, wherein, The armature is moved along the first direction to move the locking plate to the connection position.

3. The gear reduction unit according to claim 1, wherein, The armature is moved along the first direction to move the locking plate to the disconnected position.

4. The gear reduction unit according to any one of claims 1 to 3 further includes a biasing element configured to bias the locking plate in a second direction opposite to the first direction.

5. The gear reduction unit according to any one of claims 1 to 4, wherein, The support connector includes an internal spline configured to engage with the intermediate shaft.

6. The gear reduction unit according to any one of claims 1 to 5, wherein, The locking plate and the gear output each have canine teeth that mesh together when the locking plate is in the connection position.

7. The gear reduction unit according to any one of claims 1 to 6, wherein, The locking plate includes a retaining member that engages the snap-fit ​​surface of the support connector to rotatably connect the locking plate and the support connector together.

8. The gear reduction unit according to any one of claims 1 to 7, further comprising a pin extending through the support coupling between the armature and the locking plate.

9. The gear reduction unit according to claim 8, wherein, The pin is integrally formed with the locking plate.

10. The gear reduction unit according to any one of claims 1 to 9, wherein, The support coupling includes a stop member that prevents the armature from moving beyond a first position along the second direction, thereby limiting the travel of the armature relative to the support coupling.

11. A method for disconnecting a wheel axle from a drive motor, the method comprising: The axle is rotatably connected to the support connector; The torque from the drive motor is supplied to the gear output; An electromagnet that allows current to flow through the stator causes the armature to move toward the stator against the bias of the spring along the support connector; The locking plate is moved along the support connector and the armature from the connection position connected to the gear output to the disconnect position disconnected from the gear output.

12. The method according to claim 11, wherein, The spring is disposed between the locking plate and the support connector.

13. The method of claim 11, further comprising reconnecting the axle to the drive motor, wherein reconnecting the axle to the drive motor comprises stopping the supply of current to the electromagnet, thereby allowing the locking plate to move back to the connected position under the bias of the spring.

14. A method for connecting an axle to a drive motor, the method comprising: The axle is rotatably connected to the support connector; The torque from the drive motor is supplied to the gear output; as well as The locking plate is moved away from the gear output and biased toward the support connector, such that the locking plate is positioned in the disconnected position relative to the gear output.

15. The method according to claim 14, wherein, The locking plate is biased away from the gear output by a spring disposed between the locking plate and the gear output.

16. The method of claim 11, further comprising reconnecting the axle to the drive motor. Reconnecting the axle to the drive motor includes: An electromagnet that allows current to flow through the stator causes the armature to move toward the stator against the bias voltage along the support connection. as well as The locking plate, together with the armature, moves along the support connector from a disconnected position to a connected position to the gear output, wherein the locking plate, when positioned in the connected position, engages the gear output to move together with the gear output.

17. A disconnection device, comprising: A support connector includes a body extending along an axis between opposing first and second sides, the support connector defining a channel extending through the support connector along the axis, the support connector also defining a recess on the first side of the body, and the support connector defining a mounting area on the second side of the body. A stator is mounted to the support connector at an axial position between the recess and the mounting area, the stator including an electromagnet; A locking plate is disposed in the recess on the first side of the body. The locking plate is movable relative to the support connector along the axis between a first position and a second position. The locking plate includes a peripheral retaining member configured to engage a snap-fit ​​surface of the support connector to rotatably lock the locking plate to the support connector. The locking plate also includes canine teeth extending axially outward from the locking plate away from the support connector. An armature, mounted to the support connector at the mounting area, the armature being axially movable along the mounting area, the armature comprising an ferrous metal that can be attracted by an electromagnet of the stator; as well as A pin extends through the support connector between a first end and a second end, the first end of the pin being secured to the locking plate, and the second end of the pin being configured to engage the armature.

18. The disconnecting device according to claim 17, further comprising a biasing element disposed on the same side of the locking plate as the dog teeth.

19. The disconnection device according to claim 18, wherein, The ferrous metal of the armature is located on the side of the stator opposite to the locking plate.

20. The disconnection device according to claim 17, further comprising a biasing element disposed between the locking plate and the support connector.

21. The disconnection device according to claim 20, wherein, The ferrous metal of the armature and the locking plate are located on the same side of the stator.

22. The disconnecting device according to any one of claims 17 to 21, further comprising a gear output of a gear reduction unit, the gear output including canine teeth, the canine teeth of the gear output being configured to engage with the canine teeth of the locking plate when the locking plate is positioned in one of the first position and the second position, and the canine teeth of the gear output being configured to be spaced apart from the canine teeth of the locking plate when the locking plate is positioned in the other of the first position and the second position.

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