Axle Drive Mechanism with Integrated Shiftable Torque Transmission

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Solution Overview

Problem

Conventional axle transmissions in all-wheel drive vehicles experience inefficiencies and increased CO2 emissions due to load-dependent losses, which are not effectively addressed by existing technologies.

Innovation Solution

An improved axle drive mechanism with a shiftable torque transmission device that selectively interrupts and reconnects torque flow between wheels, utilizing a differential cage and form-locking elements to optimize power distribution and reduce losses, featuring a compact design with a torque transmission region between differential cage bearings and an actuator for quick mode switching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If permanent all-wheel drive is used, then all wheels are continuously driven, but load-dependent losses increase and efficiency decreases

Engineering Contradiction:
Improvecontinuous drive capabilityVSAvoidload-dependent losses
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent implements a dynamic torque transmission system where the torque transmission device can shift between connected and disconnected states. The torque transmission region is designed to be displaceable relative to the differential cage bearings, allowing the system to adapt its torque transmission characteristics based on driving conditions. This dynamic capability enables the system to disconnect from permanent all-wheel drive operation when full torque transmission is not required, thereby reducing load-dependent losses while maintaining the capability to provide continuous drive when needed.

Inventive Principle:
Principle #15Dynamics

2Loss of energy

If non-permanent all-wheel drive with switching actuation is used, then load-independent losses are reduced, but device complexity increases

Engineering Contradiction:
Improveload-independent lossesVSAvoidswitching actuation and sensor
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent merges the torque transmission function with the differential mechanism by integrating the torque transmission device directly into the differential cage structure. The torque transmission region is formed as part of the differential cage bearings arrangement, eliminating the need for separate switching actuators and sensors. This integration achieves non-permanent all-wheel drive operation through the inherent mechanical design of the torque transmission device itself, reducing device complexity while maintaining energy efficiency.

Inventive Principle:
Principle #5Merging (Combining)

3Power

If torque flow is continuously transmitted, then all wheels receive power, but power dissipation increases during non-driven wheel states

Engineering Contradiction:
Improvepower distribution to wheelsVSAvoidpower dissipation
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The patent segments the torque transmission path by providing a torque transmission device that can selectively engage or disengage specific torque transmission regions relative to the differential cage bearings. This segmentation allows the system to control torque flow to individual wheels or axle groups independently, disconnecting torque transmission to wheels that do not require drive power. By dividing the torque transmission function into controllable segments, the system minimizes power dissipation while maintaining the capability to distribute power to all wheels when required.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS10245948B2Eco 4×4 front-axle transmission having an integrated shut-off unit for all wheel drives
Publication Date: 2019.04.02 BAYERISCHE MOTOREN WERKE AG
  • US10245948B2 patent drawing
  • US10245948B2 patent drawing
  • US10245948B2 patent drawing

AI summary

An axle drive mechanism includes a driving toothed wheel, a drive mechanism housing, a differential cage, a differential gear, a first and a second output shaft, and at least one shiftable torque transmission device. The at least one shiftable torque transmission is disposed between the driving toothed wheel and the first output shaft and includes a torque transmission region. The torque transmission region is at least partially disposed between said differential cage bearings in the axial direction.