Adaptive Bearing Preload Adjustment for Axle Alignment
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Solution Overview
Problem
Current vehicle systems lack the ability to adjust bearing preload in real-time, leading to suboptimal axle alignment during varying driving conditions, which increases friction and reduces fuel mileage due to a fixed preload selected for worst-case scenarios.
Innovation Solution
An adaptive bearing preload adjustment system that includes a motor-activated adjustment assembly with ramped surfaces, allowing for dynamic adjustment of the preload force on the bearing to accommodate changing driving conditions by shifting members relative to the bearing's inner race.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed preload is selected for worst-case scenario conditions, then proper axial alignment is promoted during cornering and high torque maneuvering, but friction on the bearing increases leading to reduced fuel mileage performance
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a static fixed preload system to a dynamic adjustable preload system. The bearing preload adjustment mechanism allows the preload force to be varied in real-time based on actual driving conditions, enabling the system to optimize between alignment reliability and energy efficiency. The control system monitors parameters such as vehicle speed, steering angle, and torque to dynamically adjust the preload accordingly.
Solution Approach 2:
The patent implements parameter changes by varying the preload force parameter based on operating conditions. Instead of maintaining a constant worst-case preload, the system adjusts the preload parameter dynamically - reducing it during normal cruising conditions to minimize friction and fuel consumption, while increasing it during cornering or high-torque maneuvers to maintain proper axial alignment and bearing support.
2Reliability
If the preload is increased to promote desired axle alignment at the outer edge of the design envelope, then axial alignment is improved, but rolling resistance increases
Solution Approach 1:
The system dynamically adjusts the preload parameter based on actual operating conditions rather than maintaining a static high preload. During normal driving conditions, the preload is reduced to minimize rolling resistance. The system only increases preload dynamically when cornering or high-torque conditions are detected, thus eliminating unnecessary rolling resistance while maintaining alignment reliability when needed.
Solution Approach 2:
The control system periodically monitors driving conditions and adjusts the preload in response to changing operational requirements. This periodic adjustment ensures that high preload is applied only during specific conditions (cornering, acceleration) that require enhanced alignment, rather than continuously, thereby reducing overall rolling resistance and energy loss.
3Device complexity
If a fixed preload system is used, then the system structure remains simple, but the system cannot adapt to real-time driving conditions
Solution Approach 1:
The patent introduces dynamic adjustability to the bearing preload system through an electric motor-driven adjustment mechanism. This allows the previously static preload system to become adaptive, responding to real-time driving conditions while maintaining a relatively simple overall structure. The adjustment mechanism includes a motor, drive gear, and adjustment member that can modify the preload force without adding excessive complexity to the bearing assembly.
Solution Approach 2:
The patent replaces traditional mechanical preload adjustment methods with an electric motor-driven system. Instead of using complex mechanical linkages or manual adjustment mechanisms, the system employs an electric motor coupled with a drive gear to actuate the preload adjustment member. This substitution simplifies the control architecture while enabling precise, programmable preload adjustment based on sensor feedback from the vehicle's control system.
Data Source
AI summary
An axle assembly includes an axle housing having a passage. An axle extends through the passage. A bearing supports the axle in the passage. An adaptive bearing preload adjustment system is mounted adjacent the bearing. The adaptive bearing preload adjustment system is selectively activatable to adaptively adjust a preload force on the bearing.