Constant velocity joint with disconnect capability

Abstract

A constant velocity joint assembly includes an input shaft and an output shaft. The constant speed mechanism allows power transfer between the input shaft and the output shaft while allowing angular variation between the shafts. There is also provided a disconnect device having a first portion and a second portion that are relatively rotatable relative to each other in a disconnected state and are not relatively rotatable relative to each other in a connected state. The actuator transitions the disconnect device between a disconnect state and a connected state whereby power is transmitted between the input shaft and the output shaft in the connected state and power is not transmitted between the input shaft and the output shaft in the disconnect state. At least one bearing may be interposed between the first portion and the second portion.

Description

[0001] Cross-reference to related applications

[0002] This application is based on and claims priority to U.S. Provisional Patent Application No. 63 / 468,705, filed May 24, 2023, the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0003] This invention generally relates to constant velocity universal joints. Background Technology

[0004] Mechanisms for selectively engaging and disengaging drive axles from the wheels of a corresponding vehicle are known. For example, the basic principle may include mechanisms utilizing multiple drive axles in the drivetrain on a continuous or full-time basis. In recent years, drivetrains in which additional drive axles can be engaged and disengaged as needed or on demand have become increasingly popular for various reasons. For example, known mechanisms allow users to manually engage the vehicle's drivetrain to the wheels, which typically requires the user to leave the vehicle to complete the manual engagement. Furthermore, automated systems are known in which the vehicle's control system automatically engages and disengages the drivetrain from the wheels based on driving conditions. However, such mechanisms typically involve many complex components, and therefore their manufacture and maintenance can be complex and expensive.

[0005] The present invention recognizes and resolves considerations of existing technical structures and methods. Summary of the Invention

[0006] One aspect of the invention provides a constant velocity universal joint assembly including an input shaft and an output shaft. The constant velocity mechanism allows power transmission between the input and output shafts while allowing angular variation between the shafts. A disconnection device is also provided, having a first portion and a second portion that are rotatable relative to each other in an disconnected state and not rotatable relative to each other in an connected state. An actuator switches the disconnection device between a disconnected state and a connected state, whereby power is transmitted between the input and output shafts in the connected state and not transmitted between the input and output shafts in the disconnected state. At least one bearing may be located between the first and second portions.

[0007] In some exemplary embodiments, the constant velocity mechanism has a housing in which a shaft carrying a plurality of trunnions is received, and a first portion and a second portion are associated with the housing. At least a portion of the first portion and at least a portion of the second portion may be concentric with each other. The first portion may have an axial extension integral with the housing body, and the second portion may be concentric with the axial extension. Alternatively, the first portion and the second portion may be axially aligned with each other.

[0008] According to some exemplary embodiments, the disconnect component may include a clutch mechanism that causes selective engagement between a first portion and a second portion. The clutch mechanism itself may include a sliding collar that is slidably movable on the second portion between a disconnected state and an engaged state. An axially movable link may engage the sliding collar. The clutch mechanism may also include a linear actuator that causes axial movement of the link, thereby causing axial movement of the sliding collar.

[0009] In some exemplary embodiments, a linear actuator may include a helical actuator.

[0010] In some exemplary embodiments, the linear actuator may include a solenoid, such as a bistable solenoid.

[0011] Another aspect of the invention provides a constant velocity universal joint assembly including an input shaft and an output shaft. The constant velocity mechanism allows power transmission between the input and output shafts while allowing for angular variation between the shafts. The constant velocity mechanism has a housing in which a shaft carrying a plurality of trunnions is housed. A disconnecting device having first and second portions is also provided, the first and second portions being rotatable relative to each other in an disconnected state and not rotatable relative to each other or relative to each other in an engaged state. The first portion is integral with the housing (e.g., wholly or partially), and the disconnecting assembly includes a clutch mechanism that causes selective engagement between the first and second portions. Furthermore, an actuator switches the disconnecting device between a disconnected state and an engaged state, whereby power is transmitted between the input and output shafts in the engaged state and not transmitted between the input and output shafts in the disconnected state.

[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present disclosure and, together with the specification, serve to explain the principles of the invention. Attached Figure Description

[0013] The specification sets forth a complete and practical disclosure of the invention for those skilled in the art, including its preferred mode, with reference to the accompanying drawings, wherein:

[0014] Figure 1 This is a diagram of a half-shaft assembly based on existing technology;

[0015] Figure 2 yes Figure 1 An enlarged view of one of the constant velocity joints (CVJs) in the half-shaft assembly;

[0016] Figure 3 This is a schematic diagram of a CVJ with disconnection capability according to an embodiment of the present invention;

[0017] Figure 4 This is a schematic diagram of a CVJ with disconnection capability according to an embodiment of the present invention;

[0018] Figure 5 This is a schematic diagram of a CVJ with disconnection capability according to an embodiment of the present invention;

[0019] Figure 6 This is a schematic diagram of a CVJ with disconnection capability according to an embodiment of the present invention;

[0020] Figure 7 This is a schematic diagram of a CVJ with disconnection capability according to an embodiment of the present invention;

[0021] Figure 8 yes Figure 7 A view of an embodiment, which further shows an actuator for axially moving the CVJ between a connected state and a disconnected state.

[0022] Figure 9A and 9B The images show the disconnected and connected states, respectively. Figure 7 Examples;

[0023] Figure 10 This is a schematic diagram of a CVJ with disconnect capability according to an embodiment of the present invention; and

[0024] Figure 11 This is a schematic diagram of a CVJ with disconnection capability according to an embodiment of the present invention.

[0025] Reference numerals used repeatedly in this specification and drawings are intended to indicate the same or similar features or elements of the invention according to this disclosure. Detailed Implementation

[0026] Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each embodiment is provided by way of explanation rather than limitation. In fact, it will be apparent to those skilled in the art that modifications and variations can be made to the invention without departing from the scope and spirit of the invention. For example, features shown or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, the invention is intended to cover these modifications and variations that fall within the scope of the appended claims and their equivalents.

[0027] As background, Figure 1A prior art vehicle half-shaft assembly 10 is shown, which can be modified according to the principles of the present invention. Half-shaft 10 includes a first constant velocity joint 12 and a second constant velocity joint 14 near their respective ends. It is well known that CVJs (also called “constant velocity joints”) are used to transmit rotation from an input shaft to an output shaft when the angle between the shafts varies within a certain range. In this case, CVJ 12 is considered the “inner” CVJ because CVJ 12 is directly connected to the differential, for example, via a stubshaft 16. CVJ 12 transmits torque to an intermediate half-shaft 18, which serves as the input to CVJ 14. CVJ 14 is considered the “outer” CVJ because CVJ 14 is connected to the wheel to be driven, for example, via an output stubshaft 20. CVJ 12 and CVJ 14 have corresponding shields 22 and 24 extending between the housing (or simply "exterior") of CVJ 12 and CVJ 14 and the shaft 18 to allow angular movement while containing lubricant and protecting the interior of the CVJ from environmental contaminants.

[0028] Now refer to Figure 2 The inner CVJ 12 is typically constructed as an "insertion CVJ," meaning that the inner CVJ 12 accommodates some axial movement relative to the half-shaft 18. The insertion CVJ has a "tripod" 26 splined to the axle 18, which has three trunnions (e.g., trunnions shown as 28) extending radially and spaced 120° apart. Each trunnion carries a corresponding barrel roller bearing that interacts with the outer CVJ 32. The shaft 16 extends from the outer 32, as shown. Therefore, rotation of the shaft 16 causes rotation of the outer 32, which in turn causes rotation of the tripod 26 and thus rotation of the half-shaft 18. The outer CVJ can also be a tripod CVJ or any other suitable type, but is typically not inserted.

[0029] Embodiments of the present invention provide selective interruption of power flow via a CVJ (which may be an insertable or non-insertable CVJ). The universal joint may be a standalone CVJ or integrated into a half-shaft. (An example of an application of a standalone CVJ could be a prop shaft.) Some embodiments of the invention achieve selective power disconnection by utilizing a two-piece housing CVJ, wherein the two housings can rotate independently about the same axis when disconnected or rotate together when connected. For example, the two components may be concentric with each other.

[0030] The separation point between the two components of the CVJ housing can be in several different locations, some examples of which are shown in the accompanying drawings discussed below. A clutch mechanism is provided to selectively transmit power between them. For example, the two components can be selectively engaged in the following manner:

[0031] A translation ring, which is radially splined to one side and selectively axially splined to the other side.

[0032] A translation ring, which is radially splined to one side and selectively radially splined to the other side.

[0033] A radially movable fin that is always in contact with one side and selectively in contact with the other side.

[0034] Any other suitable clutch device as required or desired.

[0035] Using suitable actuators to move translational or radially movable components, such as:

[0036] Motor, rack and pinion, and fork.

[0037] Motor, lead screw, and shift fork.

[0038] Motor, half screw and fork.

[0039] Plunger-type solenoid valve and fork.

[0040] Toroidal solenoid and toroidal armature.

[0041] Any other suitable linear actuator or other actuator as needed or desired.

[0042] In the case of solenoids, bistable solenoids are preferably used. Solenoids can be made bistable using, for example, a permanent magnet latching system with a spring or a retractable pen-like mechanism. These bistable options offer the benefit of "failing to state" when the actuator loses power. Retractable pen mechanisms can also work with motor-based actuators.

[0043] in this regard, Figure 3A first embodiment of a CVJ 112 according to one aspect of the invention is shown. The CVJ 112 is incorporated in this embodiment into a half-shaft assembly having a short shaft 116 for connection to a differential and a half-shaft 118 extending to the outer CVJ. The CVJ 112 has an outer portion 132 having a first portion 132a with a bell (or cup) shape having a closed end and an open end. As shown, a three-ball pin 126 is received through the open end to be positioned in the bell-shaped portion. The short shaft 116 is secured to a second portion 132b of the outer portion 132. It can be seen that the first portion 132a is received in and concentric with the second portion 132b. When the clutch is disengaged, suitable bearings (e.g., bearings 134 and 136) allow relative rotation between the first portion 132a and the second portion 132b. A flexible sheath 122 extends between the first portion 132a and the half-shaft 118.

[0044] As shown in the figure, the clutch mechanism can connect parts 132a and 132b radially, as shown in 138, or connect parts 132a and 132b axially, as shown in 140. Any suitable clutch mechanism can be used. Some examples include parking pawl type, clutch-equipped type, axial synchronizer type, clutch plate type, etc. When parts 132a and 132b are connected (i.e., when the clutch mechanism is engaged), they rotate together.

[0045] Figure 4 A second embodiment of the CVJ 212 according to one aspect of the invention is shown. Because the CVJ 212 is similar to the CVJ 112 in many respects, similar elements will be indicated by reference numerals one hundred greater than those of the CVJ 112. However, in this case, the first portion 232a has a larger axial width than the first portion 132a, thus allowing for a wider spacing between bearings 234 and 236. A wider extension of the bearings may be desired to provide better system stiffness. Note that bearing 234 is located on the stepped descending region 242 of the first portion 232a in this case. The stepped descending region 242 is formed as an axial extension from the bell-shaped portion of the first portion 232a. Radial and / or axial engagement can be provided, as shown in 238 and 240.

[0046] Figure 5A third embodiment of the CVJ 312 according to one aspect of the invention is shown. Because the CVJ 312 is similar to the CVJ 212 in many respects, similar elements will be indicated by reference numerals one hundred greater than those of the CVJ 212. However, in this case, another axial extension 344 is located inside the stepped region 342 where the bearing 334 is located. The extension 344 may or may not have an outer diameter smaller than that of region 342, and the extension 344 provides another potential location for the clutch mechanism, as shown in 346.

[0047] Figure 6 A fourth embodiment of the CVJ 412 according to one aspect of the invention is shown. Because the CVJ 412 is similar to the CVJ 312 in many respects, similar elements will be indicated by reference numerals one hundred greater than those of the CVJ 312. However, in this case, the first portion 432a has a longer axial extension 444, where bearings 434 and 436 are both located. As a result, the second portion 432b surrounds only the extension 444, and not the bell-shaped portion of the first portion 432a where the three ball pins 426 are located. This embodiment may be advantageous in applications with more limited radial space. Furthermore, this embodiment allows for another potential location for radial and / or axial clutch mechanisms, as shown in 448a and 448b.

[0048] Now refer to Figure 7 Another embodiment of the invention provides a CVJ 512 in which a disconnect feature is provided on the inner "insertion" side of the CVJ for encapsulation and environmental protection. In this respect, the CVJ seal can be moved to the outside of the assembly. As shown, a translational collar 550 with axial splines on its inner diameter is located on the outer diameter of a second portion 532b with complementary splines. If a shift collar is brought into the drive unit, no additional seal is required. ATF can also be used for lubrication of bearings and interfaces.

[0049] In this configuration, the supports for the fixed and offset sides of the assembly are shared between ball bearings 534, which are sealed ball bearings that slide in a fit on the extension 542 of the second portion 532b. Furthermore, a thrust bearing 536 (here, an NRB thrust bearing) may be located between the axially opposing faces of portions 532a and 532b. A wave spring 552 may be provided to remove any clearance in the assembly that could cause noise from the thrust bearing or ball bearing when it is in a disengaged state.

[0050] Now for reference Figure 8 In this embodiment, the collar 550 uses a suitable connecting rod 554 in the disconnected position and the connected position (respectively). Figure 9A and9B The link 554 moves axially via a suitable linear actuator 556. In this case, the link 554 is configured as a fork-shaped element with an elongated intermediate portion 558. An arcuate portion 560 is located at the distal end of the elongated portion 558, and in this case, the arcuate portion 560 is approximately semi-circular. The arcuate portion 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 is allowed to rotate with one or both of the input and output shafts (depending on whether it is in a disconnected or connected state), but the link 554 remains rotatably fixed. However, the reciprocating axial movement of the link 554 via the actuator 556 causes the collar 550 to shift between the connected and disconnected positions.

[0051] Instead of the spline on the first part 532a, the collar 550 may include, for example, axial jaws to engage with a suitable opening on the flange 558 of the first part 532a.

[0052] Figure 10 Another embodiment of CVJ 612 is shown, wherein the collar 650 has an axial splined or surface splined engagement between the short shaft 616 and the outer portion 632a of the CVJ. The ball bearing 634 allows relative rotation in the disconnected state. A suitable actuator is used to initiate disconnection and connection.

[0053] Figure 11 Another embodiment of the CVJ 712 is shown, wherein a collar 750 is splinedly connected to the outer surface of the CVJ outer portion 732a. A ball bearing 734 allows relative rotation in the disconnected state and maintains alignment in both the disconnected and connected states. A suitable actuator is used to initiate disconnection and connection.

[0054] While one or more preferred embodiments of the present invention have been described above, those skilled in the art should understand that various modifications and variations can be made to the present invention without departing from the scope and spirit of the invention.

Claims

1. A constant velocity universal joint assembly, comprising: Input and output axes; A constant velocity mechanism that allows power to be transmitted between the input shaft and the output shaft, while also allowing for changes in the angle between the shafts; A disconnection device having a first part and a second part, the first part and the second part being able to rotate relative to each other in a disconnected state and not being able to rotate relative to each other in a connected state; and An actuator that causes the disconnection device to switch between the disconnected state and the connected state. Therefore, in the connected state, the power is transmitted between the input shaft and the output shaft, and in the disconnected state, the power is not transmitted between the input shaft and the output shaft.

2. The constant velocity universal joint assembly of claim 1, wherein the constant velocity mechanism has a housing, a shaft carrying a plurality of trunnions is received in the housing, and the first portion and the second portion are associated with the housing.

3. The constant velocity universal joint assembly according to claim 2, wherein at least a portion of the first portion and at least a portion of the second portion are concentric with each other.

4. The constant velocity universal joint assembly according to claim 3, wherein the first portion has an axial extension integral with the housing, and the second portion is concentric with the axial extension.

5. The constant velocity universal joint assembly according to claim 2, wherein the first portion and the second portion are axially aligned with each other.

6. The constant velocity universal joint assembly of claim 1, wherein the disassembly assembly includes a clutch mechanism that causes selective engagement between the first portion and the second portion.

7. The constant velocity universal joint assembly of claim 1, wherein the clutch mechanism includes a sliding collar that is slidably movable on the second portion between the disconnected state and the connected state.

8. The constant velocity universal joint assembly of claim 6, wherein the clutch mechanism includes an axially movable link that engages the slidable collar.

9. The constant velocity universal joint assembly of claim 7, wherein the clutch mechanism includes a linear actuator that causes axial movement of the connecting rod, thereby causing axial movement of the sliding collar.

10. The constant velocity universal joint according to claim 8, wherein the linear actuator comprises a screw actuator.

11. The constant velocity universal joint according to claim 8, wherein the linear actuator comprises a solenoid.

12. The constant velocity universal joint according to claim 8, wherein the solenoid comprises a bistable solenoid.

13. The constant velocity assembly of claim 1, wherein at least one bearing is located between the first portion and the second portion.

14. A constant velocity universal joint assembly, comprising: Input and output axes; A constant velocity mechanism that allows power to be transmitted between the input shaft and the output shaft, while allowing for changes in the angle between the shafts, the constant velocity mechanism having a housing in which a shaft carrying a plurality of trunnions is received; A disconnecting device having a first part and a second part, the first part and the second part being rotatable relative to each other in a disconnected state and being unable to rotate or rotate relative to each other in a connected state, the first part being integral with the housing, the disconnecting assembly including a clutch mechanism that causes selective engagement between the first part and the second part; and An actuator that causes the disconnection device to switch between the disconnected state and the connected state. Therefore, in the connected state, the power is transmitted between the input shaft and the output shaft, and in the disconnected state, the power is not transmitted between the input shaft and the output shaft.

15. The constant velocity universal joint assembly of claim 14, wherein at least a portion of the first portion and at least a portion of the second portion are concentric with each other.

16. The constant velocity universal joint assembly of claim 15, wherein the first portion is formed as an axial extension integral with the bell-shaped portion of the housing, and the second portion is concentric with the axial extension.

17. The constant velocity universal joint assembly of claim 15, wherein the first portion and the second portion are axially aligned with each other.

18. The constant velocity universal joint assembly of claim 14, wherein the clutch mechanism includes a sliding collar that is slidably movable on the second portion between the disconnected state and the connected state.

19. The constant velocity universal joint assembly of claim 18, wherein the clutch mechanism includes an axially movable link that engages the slidable collar.

20. The constant velocity universal joint assembly of claim 19, wherein the clutch mechanism includes a linear actuator that causes axial movement of the sliding collar.

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