Drive Axle Assembly Disengagement Mechanism
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Solution Overview
Problem
Existing drive axle assemblies lack a mechanism to efficiently disengage and reengage torque transmission, leading to energy losses and reduced fuel efficiency, especially in vehicles with tandem axle configurations.
Innovation Solution
A disengageable axle assembly with a wheel axle disconnect unit and an interaxle differential unit that allows selective coupling and decoupling of torque transmission between axle assemblies, utilizing actuators and gear mechanisms to manage torque distribution and compensate for speed differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If torque transmission is continuously maintained in tandem axle assemblies, then driving force is always available, but energy losses increase and fuel efficiency decreases
Solution Approach 1:
The axle assembly incorporates a disconnect mechanism that dynamically transitions between engaged and disengaged states based on driving conditions. The actuator system enables the axle to switch from a fixed torque transmission state to a variable state, allowing torque to be disconnected when not needed, thereby reducing energy losses and improving fuel efficiency.
Solution Approach 2:
The drive system is segmented into independently controllable axle assemblies, each with its own disconnect mechanism. This allows selective engagement of individual axles based on traction requirements, enabling the vehicle to operate with fewer driven wheels when possible, thus reducing overall energy consumption while maintaining adequate driving force.
2Use of energy by moving object
If axle assemblies are disengaged to reduce energy consumption, then fuel economy improves, but torque transmission capability is reduced
Solution Approach 1:
The system dynamically adjusts torque transmission by engaging or disengaging individual axle assemblies based on real-time driving conditions. When high torque is needed, axles are engaged; when traction is sufficient or energy conservation is prioritized, axles are disengaged. This dynamic control allows the system to optimize the balance between power delivery and energy consumption.
Solution Approach 2:
The disconnect mechanism changes the operational parameters of the axle assembly by altering the torque transmission state. The actuator system modifies the mechanical engagement parameters, allowing the axle to transition between full torque transmission, partial torque transmission, and complete disengagement, thereby enabling flexible control over both power delivery and energy consumption.
3Use of energy by moving object
If a disconnect mechanism is added to enable selective engagement, then fuel efficiency improves, but device complexity increases
Solution Approach 1:
The disconnect functionality is segmented into modular units integrated with each axle assembly. Each axle has its own compact disconnect mechanism and actuator, allowing independent control without requiring a complex centralized system. This modular approach distributes the complexity across multiple simple, identical units rather than one complex control system.
Solution Approach 2:
The disconnect mechanism is designed as a multi-functional component that integrates torque transmission, disengagement, and reengagement capabilities in a single system. The actuator serves multiple functions including activating the disconnect clutch, controlling the differential lock, and managing torque distribution, thereby reducing the need for separate dedicated components for each function.
Data Source
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AI summary
A drive axle assembly that may include an input shaft, an output shaft, a lock collar, and a pinion. The actuator unit may move the lock collar between a first position in which the torque is transmitted from the input shaft to the pinion and a second position in which torque is not transmitted to the pinion.