Vehicle Axle Rotary Joint With Slip Clutch Overload Protection
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Solution Overview
Problem
Existing vehicle axles with electric drives face mechanical and electrical overloading during abruptly changing driving conditions due to torque exceeding limits, leading to potential component failure.
Innovation Solution
A vehicle axle design incorporating a torque-limiting element, such as a slip clutch, within a rotary joint that disengages when torque exceeds static friction, combined with a rotation-dependent freewheel to manage power flow directionally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid axle structure with rotary shafts protected within axle tubes is used, then the rotary shafts operate free from lateral forces or bending loads and transmit torques effectively, but the torques acting on the rotary shafts can exceed their limits during abruptly changing driving conditions, resulting in mechanical or electrical overloading
Solution Approach 1:
A torque-limiting element is integrated into the rotary joint to prevent torque from exceeding a predetermined limit. This element acts as a protective mechanism that disengages or slips when torque exceeds the static friction between friction surfaces, thereby cushioning the system against overload before damage can occur to the electrical machine or drive components.
Solution Approach 2:
The torque-limiting element serves as an intermediary component between the drive shaft and the wheel head. It mediates the torque transmission by allowing controlled slippage or disengagement when torque exceeds the predetermined limit, thus protecting the electrical machine while still transmitting torque during normal operation.
2Reliability
If a torque-limiting element such as a slip clutch is introduced to prevent overloading, then torque transmission is limited and overloading is prevented, but the device complexity increases due to additional components in the rotary joint
Solution Approach 1:
The torque-limiting element is merged with the rotary joint structure, combining the functions of torque transmission and torque limitation within a single integrated component. This integration reduces the need for separate protective mechanisms and simplifies the overall structure compared to having independent torque-limiting and rotary joint components.
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 design effectively prevents mechanical and electrical overloading by limiting torque transmission, ensuring reliable operation under varying driving conditions.
Implementation Method 1
the torque-limiting element, in the form of a slip clutch, comprises two coupling partners with friction surfaces that rest against each other under spring load. If the torque exceeds the static friction at the friction surfaces, the clutch disengages
Implementation Method 2
two coupling partners with friction surfaces that rest against each other under spring load
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The vehicle axle comprises wheel heads (3) rotatably mounted on axle stubs (2) at both axle ends, an electrical device (8) arranged in a central section of the vehicle axle, which includes an electric machine (10) operable in motor and/or generator mode, and a rotary connection (18) extending through the axle stub (2) that connects the wheel head (3) to the power output or input of the electrical device (8). The rotary connection (46) includes a torque-limiting element, such as a slip clutch, and preferably also an element (30) that either blocks or releases the power flow depending on the direction of rotation.