Actuator Pivot Link Eccentric Knob Spline Sleeve Shift
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Solution Overview
Problem
Existing mechanical locking differentials in UVs and ATVs require accurate assembly of small gears and a sliding rack, which can lead to gear slippage and damage, and are difficult to disassemble and reassemble without removing the differential from the vehicle, resulting in a shorter service life.
Innovation Solution
An actuator system with an eccentric knob that moves through less than 360° of rotation, coupled to a pivot link, slide block, and shifting fork, allowing for precise control of the spline sleeve to change drive modes between two-wheel drive, four-wheel drive with differential active, and four-wheel drive with differential locked, using a lightweight and compact design with a housing that protects the motor and gear train from dirt and grime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a small electric motor with gear train and sliding rack is used to actuate the shifting fork, then the actuator is light and compact, but accurate assembly is required which can cause gear slippage and damage
Solution Approach 1:
The actuator is divided into modular components: electric motor, pivot link, slide block, and shifting fork. This segmentation allows each component to be manufactured and assembled separately, reducing the need for highly precise overall assembly while maintaining compactness and light weight.
Solution Approach 2:
The pivot link serves as an intermediary mechanism between the motor's rotational output and the slide block's linear motion. This intermediary converts the motion type and provides mechanical advantage, reducing the precision requirements for direct gear-to-rack alignment while maintaining effective actuation.
2Volume of moving object
If small gears and sliding rack are used in the actuator, then the design is compact, but disassembly and reassembly is difficult without removing the differential from the vehicle
Solution Approach 1:
The actuator components are segmented into separately mountable units that can be accessed and serviced independently. The pivot link, slide block, and shifting fork can be disassembled and reassembled without removing the entire differential assembly from the vehicle, facilitating easier maintenance while maintaining a compact overall design.
3Ease of operation
If the spline sleeve, shifting fork or gears bind or fail to smoothly shift, then the parts can be easily damaged, but the service life of the actuator is reduced
Solution Approach 1:
The pivot link and slide block design incorporates features that cushion and distribute forces during the shifting operation. This beforehand cushioning prevents binding and sudden impacts that could damage the spline sleeve, shifting fork, or gears, thereby extending the actuator's service life while maintaining smooth shifting operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The actuator system provides reliable and easy-to-assemble control of drive modes, reducing the risk of gear damage and extending service life, while being lightweight and resistant to environmental contaminants, facilitating easier assembly and maintenance.
Implementation Method 1
An output link from the electronic motor of the actuator, such as an eccentric knob, moves through less than 360° of rotation between a first circumferential end point and a second circumferential end point
Implementation Method 2
The motion of this output link is coupled to a middle section of a pivot link, to pivot the pivot link so an end portion of the pivot link moves further than the output link
Data Source
AI summary
An actuator is used to longitudinally move a spline sleeve for controlling drive mode of a differential on an off-road vehicle. The actuator's motor rotates an eccentric knob through a drive train including intermediate gears and a worm gear. The eccentic knob is linked to the spline sleeve through a torsion spring carried on a pivot plate, with legs of the torsion spring pushing a slide block, transferring a moment provided by the eccentric knob into a linear slide force. The pivot plate and torsion spring are jointly mounted on the actuator housing by a hub, opposite the rotational axis of the eccentric knob from the slide block. The slide block includes a contact which completes a circuit through conductive pads on the actuator housing, so the position of the slide block can be directly sensed.