Cutting module
A compact and robust disconnect module with an electric actuator-controlled shift sleeve addresses inefficiencies by easily integrating into the drivetrain, minimizing energy loss and design changes.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- BORGWARNER SWEDEN AB
- Filing Date
- 2024-07-03
- Publication Date
- 2026-07-03
AI Technical Summary
Existing disconnect devices in vehicles are not compact, robust, and modular, leading to inefficiencies in energy consumption and requiring significant design changes when integrated into the drivetrain.
A compact, robust disconnect module that includes a connecting sleeve and shift sleeve with splines, controlled by an electric actuator, allowing easy integration into the drivetrain without altering the main system design.
The module efficiently disconnects wheel axles from the differential, reducing energy loss and maintaining a compact, modular design with minimal impact on the drivetrain components.
Smart Images
Figure 2026522015000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a disconnect module. In particular, the present invention relates to a disconnect module configured to disconnect a vehicle's drive line from a related wheel of the vehicle.
Background Art
[0002] In the automotive industry, there is a need to improve energy efficiency. Particularly in modern vehicles, energy consumption is a major concern, and it is desirable to be able to disconnect certain components when drive torque is not required in order to minimize losses in the drivetrain.
[0003] Furthermore, a device for enabling disconnection preferably remains as small as possible so as to fit within the usually very limited available space.
[0004] When addressing these two objectives, it is also desirable that the disconnect device be of a modular design such that it can be added to the topology of the drivetrain without requiring significant design changes.
[0005] A solution to address these problems in combination has not been suggested so far, and in view of the above problems of the prior art, an improved disconnect device is needed.
Summary of the Invention
[0006] In view of the above, an object of the present invention is to provide a disconnect module that is compact, robust, simple, and can be easily added to a vehicle's drive line. Furthermore, an object of the present invention is to provide a disconnect module configured to disconnect a wheel axle from the output of a differential.
[0007] According to a first aspect, a cutting module for a vehicle is provided. The cutting module comprises a connecting sleeve having a first end configured to rotate freely with respect to an input shaft and a second end rotatably connected to an output shaft. The cutting module further comprises a shift sleeve having a first end rotatably connected to an input shaft, the shift sleeve being axially movable to rotatably connect the shift sleeve to the connecting sleeve or to disconnect it from the connecting sleeve.
[0008] The cutting module may further include two bearings that support the first and second ends of the connecting sleeve, respectively.
[0009] The cutting module may further include a bearing support ring that is rotatably connected to the input shaft and supports the first end of the connecting sleeve.
[0010] The shift sleeve may have at least one row of inner splines, and the connecting sleeve may have the same number of rows of outer splines. Preferably, the number of splines is three.
[0011] The cutting module may further include an electric actuator configured to control the axial position of the shift sleeve.
[0012] The shift sleeve may be positioned radially outward from the connecting sleeve.
[0013] According to a second embodiment, a vehicle or axle is provided. The vehicle or axle comprises a cutting module according to the first embodiment.
[0014] The vehicle or axle may further include a differential and a wheel shaft, and the cutting module may be configured to cut the wheel shaft away from the differential.
[0015] The differential gear may include side gears that form the input shaft for the cutting module.
[0016] The side gear may extend within the hollow shaft, and the shift sleeve may be rotatably connected to the hollow shaft. [Brief explanation of the drawing]
[0017] The present invention will be described in more detail below with reference to the attached drawings. [Figure 1] Figure 1 is a schematic diagram of a vehicle according to one embodiment. [Figure 2] Figure 2 is a schematic cross-sectional view of a cutting module attached to a differential according to one embodiment. [Figure 3] Figure 3 is a cross-sectional view of a disconnected module in a connected state. [Figure 4] Figure 4 is a cross-sectional view of the cut module in its cut state. [Figure 5a] Figure 5a is a schematic cross-sectional view of a vehicle drive shaft according to one embodiment, which includes a cutting module in a connected and disconnected state. [Figure 5b] Figure 5b is a schematic cross-sectional view of a vehicle drive shaft according to one embodiment, which includes a cutting module in connected and disconnected states. [Modes for carrying out the invention]
[0018] Figure 1 schematically shows vehicle 1. Vehicle 1 is shown only as an example, and various configurations are possible for the concepts described herein. Vehicle 1 comprises a front axle 3 and a rear axle 6. The front axle 3 is provided with two front axle wheel shafts 4a and 4b, which support the left and right front wheels 5a and 5b, respectively. The rear axle 6 is provided with two rear axle wheel shafts 7a and 7b, which support the left and right rear wheels 8a and 8b, respectively.
[0019] The front axle 3 may be a driven axle. For this purpose, the front axle 3 is driven by a torque source such as an electric traction motor 10. The electric traction motor 10 supplies drive torque to a differential device 20 connected to the left and right front wheel shafts 4a and 4b, respectively, in order to drive the front wheels 5a and 5b.
[0020] The rear axle 6 may be a driven axle. For this purpose, the rear axle 6 is driven by a torque source such as an electric traction motor 30. The electric traction motor 30 supplies drive torque to a differential device 20 arranged on the rear axle 6 connected to the left and right rear wheel shafts 7a and 7b, respectively, in order to drive the rear wheels 8a and 8b.
[0021] For each driven wheel shaft 4a, 4b, 7a, 7b, upstream torque paths form drive lines 40, 50. For each front wheel shaft 4a, 4b, the front drive line 40 is formed by a torque source, i.e., an electric traction motor 10, a front axle differential device 20, and any further components that may be required for proper torque transmission. For each rear wheel shaft 7a, 7b, the rear drive line 50 is formed by a torque source, i.e., an electric traction motor 30, a rear axle differential device 20, and any further components that may be required for proper torque transmission.
[0022] The cutting module 60 is provided to enable the drive lines 40, 50 to be disconnected from the associated wheel shafts 4a, 4b, 7a, 7b when the drive lines 40, 50 are not used. The cutting module 60 is arranged to connect the wheel shafts 4a, 4b, 7a, 7b to the associated differential device 20. In such applications, the differential device forms an input shaft for the cutting module 60, and the wheel shafts 4a, 4b, 7a, 7b form an output shaft for the cutting module 60. [[ID=`13]]
[0023] Although an electrical drive line is described with reference to FIG. 1, it should be noted that the disconnect module 60 can operate equally well with any type of drive line that can be a mechanical drive line, an electrical drive line, or a hybrid drive line.
[0024] In FIG. 2, the disconnect module 60 is schematically shown, particularly by its connection to the differential 20. The differential 20 is preferably an open differential having a cage 21 that receives an input drive torque. Inside the cage 21, a number of spider gears 22 are arranged. These rotate with the cage 21 and engage two opposing side gears 23. Each side gear 23 extends from the cage 21 and forms part of or is connected to the respective wheel shafts 4a, 4b, 7a, 7b.
[0025] The disconnect module 60 is connected to the wheel shafts 4b, 7b and the side gear 23 of the differential 20. When the disconnect module 60 is in the connected mode, the wheel shafts 4b, 7b are rotatably connected to the side gear 23 of the differential 20. When the disconnect module 60 is in the disconnect mode, the wheel shafts 4b, 7b are rotationally disconnected from the side gear 23 of the differential 20.
[0026] When the disconnect module 60 is in the disconnect mode, the torque sources 10, 20 are not drivingly connected to the wheels 5a, 5b, 8a, 8b of the drive lines 40, 50, so it is possible to stop the torque sources 10, 20.
[0027] The disconnect module 60 is shown in more detail in FIG. 3. The side gear 23 of the differential 20 extends by means of a hollow shaft 24. The disconnect module 60 comprises a connection sleeve 61 having a first end 62 in the form of a shaft that is inserted into the hollow shaft 24 of the side gear 23.
[0028] The first end 62 rotates freely relative to the hollow shaft 24. For this purpose, the cutting module 60 includes a bearing support ring 63 and an associated bearing 64. The bearing support ring 63 is connected to the hollow shaft 24, for example, via a spline, and the first end 62 of the connecting sleeve 61 is connected to the bearing support ring 63 by the bearing 64.
[0029] The connecting sleeve 61 extends from a first end 62 to a second tubular end 65. The tubular end 65 is configured to connect to the wheel shafts 4b and 7b, for example, via a spline. The tubular end 65 is supported by a second bearing 66 positioned between the tubular end 65 and the housing 67. Thus, the wheel shafts 4b and 7b always rotate together with the connecting sleeve 61.
[0030] The cutting module 60 further comprises an axially displaceable shift sleeve 68. The shift sleeve 68 has a first end 69 that is rotationally secured to the hollow shaft 24 of the side gear 23 of the differential 20. Such a connection may be provided, for example, by a spline connection. The shift sleeve is hollow and extends from a first end 69 to a second end 70 that surrounds the first end 62 of the connecting sleeve 61. The second end 70 of the shift sleeve 68 is hollow but has a larger diameter than the first end 69 of the shift sleeve 68.
[0031] The second end 70 of the shift sleeve 68 surrounds, at least to some extent, the tubular end 65 of the connecting sleeve 61.
[0032] The shift sleeve 68 rotates continuously with the side gear 23 of the differential 20 and can be selectively connected to the connecting sleeve 61. This is achieved by radial engagement between the shift sleeve 68 and the connecting sleeve 61. In the illustrated example, the shift sleeve 68 is provided with three rows of internal splines 71.
[0033] Correspondingly, the connecting sleeve 61 is provided with the same number of outer splines 72. Preferably, each row of splines 71, 72 has an axial length smaller than the axial distance between two adjacent rows of splines 71, 72.
[0034] In Figure 3, the cutting module 60 is shown in connection mode. In this position, the position of the shift sleeve 68 is controlled so that the row of splines 71 of the shift sleeve 68 is axially aligned with the row of splines 72 of the connection sleeve 61.
[0035] Note that the illustrated example has three columns, splines 71 and 72, but any number of columns can be considered.
[0036] In the connection mode shown in Figure 3, the connection sleeve 61 (and thus the connected wheel shafts 4b and 7b) is locked to the side gear 23 by the shift sleeve 68.
[0037] In Figure 4, the cutting module 60 is shown in cutting mode. In this mode, the shift sleeve 68, which is locked to the side gear 23, does not engage with the connecting sleeve 61, so the connecting sleeve 61 (and thus the connected wheel shafts 4b and 7b) is cut from the side gear 23.
[0038] As is clear from Figure 4, the axial position of the shift sleeve 68 is shifted so that the row of splines 71 of the shift sleeve 68 is no longer axially aligned with the row of splines 72 of the connecting sleeve 61.
[0039] The position of the shift sleeve 68 can be controlled by an electric actuator 80. In the example shown in Figure 4, the electric actuator 80 comprises a rotating shaft 81 on which an eccentric pin 82 is provided. The eccentric pin 82 extends radially outward from the shift sleeve 68 and is located within a space defined axially. This space is formed by two radial projections 83, 84 on the outside of the shift sleeve 68.
[0040] When actuator 80 is controlled, the rotating shaft 81 rotates, thereby causing axial movement of the eccentric pin 82, which in turn pushes either of the radial projections 83, 84 (depending on the direction of rotation). This achieves axial movement of the shift sleeve 68, resulting in engagement or disengagement of the rows of splines 71, 72.
[0041] Referring to Figure 5a, the vehicle axle with the cutting module 60 connected is schematically shown. The driving torque from the electric motor 10 rotates the cage of the differential 10, which in turn rotates the side gear 23. On the right side, the right wheel shafts 4a and 7a are rotatably and permanently connected to the right side gear 23. On the left side, the cutting module 60, in its connected state, rotatably connects the left wheel shafts 4b and 7b to the left side gear 23, as previously described. The arrows indicate the direction in which the wheel shafts 4a-b and 7a-b rotate relative to the electric motor 10.
[0042] In Figure 5b, the same vehicle axle is shown, but the cutting module 60 is in the cut state here. When the electric motor is not rotating, the differential cage no longer rotates. This is indicated by the intersection of dashed lines on these stationary components.
[0043] Since the shift sleeve 68 is fixed to the differential in the rotational direction, the shift sleeve 68 rotates in the opposite direction to the wheel shafts 4 and 7b, as indicated by the arrows.
[0044] This disclosure provides an extremely compact, robust, and simple cutting module 60 that forms a shaft cutting system as a modular plug-in on an open differential. It has very little impact on the original system design, thereby enabling modularity as there is no impact on the main parts of the differential, and in fact only one side gear of the differential is affected.
[0045] Furthermore, the present invention provides a cutting module that is semi-integrated with the differential by a shift sleeve 68, preferably in combination with a bearing support ring 63. Since these two components are received by the side gear 23 of the differential 20, an extremely compact solution is provided. The present invention also reduces the need for additional shafts and bearings.
Claims
1. A cutting module (60) for a vehicle (1), A connecting sleeve (61) having a first end (62) configured to rotate freely with respect to the input shafts (23, 24) and a second end (65) rotatably connected to the output shafts (4b, 7b), A shift sleeve (68) having a first end (69) rotatably connected to the input shafts (23, 24) is provided, The shift sleeve (68) is a cutting module that is axially movable to rotatably connect the shift sleeve (68) to the connecting sleeve (61) or to cut it off from the connecting sleeve (61).
2. The cutting module (60) according to claim 1, further comprising two bearings (64, 66) that support the first and second ends (62, 65) of the connecting sleeve (61), respectively.
3. The cutting module (60) according to claim 1 or 2, further comprising a bearing support ring (63) rotatably connected to the input shafts (23, 24) and supporting the first end (62) of the connecting sleeve (61).
4. The cutting module (60) according to any one of claims 1 to 3, wherein the shift sleeve (68) comprises at least one row of inner splines (71), and the connecting sleeve (61) comprises the same number of rows of outer splines (72).
5. The cutting module (60) according to any one of claims 1 to 4, further comprising an electric actuator (80) configured to control the axial position of the shift sleeve (68).
6. The cutting module (60) according to any one of claims 1 to 5, wherein the shift sleeve (68) is positioned radially outward of the connecting sleeve (61).
7. A vehicle axle (3, 6) comprising the cutting module (60) according to any one of claims 1 to 6.
8. The vehicle axle (3, 6) according to claim 7, further comprising a differential (20) and wheel shafts (4b, 7b), wherein the cutting module (60) is arranged to cut the wheel shafts (4b, 7b) from the differential (20).
9. The vehicle axle (3, 6) according to claim 8, wherein the differential gear (20) comprises a side gear (23) that forms the input shaft (23, 24) for the cutting module (60).
10. The vehicle axle (3, 6) according to claim 9, wherein the side gear (23) extends within the hollow shaft (24), and the shift sleeve (68) is rotatably connected to the hollow shaft (24).