Axle Disconnect Assembly Torque Interruption
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Solution Overview
Problem
Conventional automotive powertrain systems face challenges in efficiently managing torque distribution between drivelines, leading to parasitic losses and increased complexity, particularly in transitioning between two-wheel-drive and four-wheel-drive modes, with existing disconnect systems being bulky and costly to manufacture.
Innovation Solution
The axle disconnect assembly incorporates a clutch assembly and an electromagnetic actuator with a slider that moves between stable positions to selectively engage or disengage rotational torque between the output shaft and axle shaft, allowing for efficient torque interruption without continuous electrical supply, minimizing packaging size and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional disconnect systems are used to interrupt rotational torque between drivelines, then torque distribution control is achieved, but device size and manufacturing cost increase
Solution Approach 1:
The patent combines the disconnect mechanism directly into the differential assembly, merging previously separate components (disconnect mechanism, differential, driveshaft connection) into a single integrated unit. This eliminates the need for separate disconnect housings and reduces overall system packaging volume while maintaining torque distribution control capabilities between two-wheel-drive and four-wheel-drive modes
Solution Approach 2:
The differential assembly is designed to perform multiple functions: it serves as both the differential mechanism for torque split between wheels and the disconnect mechanism for interrupting torque to the driveline. The same housing and structural elements support both functions, reducing the need for additional dedicated components and simplifying the overall drivetrain architecture
2Reliability
If continuous electrical supply is used to maintain actuator position in disconnect systems, then reliable torque interruption is achieved, but energy consumption increases
Solution Approach 1:
The electromagnetic actuator operates in a periodic manner rather than continuously: electrical power is applied only momentarily to move the armature between discrete positions (engaged/disconnected), after which the armature maintains its position through mechanical stability without continuous electrical supply. This converts continuous energy consumption into periodic energy input with mechanical energy maintenance in between
Solution Approach 2:
The electromagnetic actuator design allows the armature to self-maintain its positioned state once moved by electrical actuation. The armature's position is held by mechanical forces (magnetic attraction in the engaged state or spring/mechanical retention in the disconnected state) without requiring continuous electrical power, enabling the system to serve itself by maintaining state without external energy input
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
This solution enhances powertrain performance by enabling simple, space-efficient torque interruption, reducing parasitic losses, and lowering manufacturing costs while improving vehicle efficiency, weight, and drivability across various driving conditions.
Implementation Method 1
an electromagnetic actuator with an armature selectively movable between a first position and a second position
Data Source
AI summary
An axle disconnect assembly for translating rotational torque between an output shaft and an axle shaft of a vehicle driveline; including: disconnect housing and a clutch supported therein. The clutch is disposed in selective torque translating relationship between the output shaft and the axle shaft, and is movable between: an engaged configuration wherein torque is translated between the output shaft and the axle shaft; and a disengaged configuration wherein torque is interrupted between the shafts. An electromagnetic actuator is provide and has a slider selectively movable between a first stable position and a second stable position. The actuator is disposed in force translating relationship with the clutch such that movement from one stable position to the other stable position causes corresponding movement of the clutch between the configurations so as to selectively translate rotational torque between the output shaft and the axle shaft.