Actuator Coupling Mechanism Tool-less Axial Engagement
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Solution Overview
Problem
Conventional actuator coupling mechanisms for multi-mode drive modules require substantial disassembly to switch between propulsion and torque-vectoring modes, necessitating an improved coupling method that is tool-less and efficient.
Innovation Solution
The actuator coupling mechanism includes a linkage with a U-shaped recess and a circumferentially extending groove, along with mating drive lugs, allowing for tool-less coupling between the shift element and the linear motor, enabling axial movement without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional coupling methods are used to connect the linear actuator to the shift fork, then the actuator can be coupled to the shift fork, but substantial disassembly of the drive module is required to remove the shift fork
Solution Approach 1:
The coupling mechanism is divided into separate modular components: a coupling element with a U-shaped recess, a rod with a circumferentially extending groove, and drive lugs. These segmented parts can be assembled and disassembled independently without requiring disassembly of the entire drive module, resolving the contradiction between ease of coupling and device complexity.
Solution Approach 2:
The rod is received into the U-shaped recess of the coupling element, with the drive lug extending into the circumferential groove for interlocking. This nested configuration allows compact assembly while maintaining ease of coupling through the tool-less design, and enables simple removal without substantial disassembly.
2Ease of operation
If conventional coupling methods are used, then the shift fork can be connected to the actuator, but tool-less coupling is not achieved
Solution Approach 1:
The drive lugs are designed to automatically engage with the circumferential groove when the rod is inserted into the U-shaped recess, creating a self-aligning, tool-less coupling mechanism. The complementary geometries of the drive lug and groove ensure proper positioning without requiring external tools or complex assembly procedures.
3Ease of operation
If the actuator coupling mechanism uses a linkage with U-shaped recess and circumferential groove, then tool-less coupling is achieved, but the structural complexity of the coupling components increases
Solution Approach 1:
The coupling components feature localized geometric features (U-shaped recess, circumferential groove, drive lugs) at specific locations rather than complex overall structures. This local differentiation provides the necessary coupling functionality while keeping the rest of the components simple and easy to manufacture.
Data Source
AI summary
An actuator coupling mechanism (ACM) for an actuator of the type that can be employed in a drive module. The ACM has first and second portions that are coupled in an axial direction by dropping one portion into the other portion such that mating features on the two portions engage one another in a tool-less manner.