Bi-stable Latching Mechanism for Axle Disconnect Apparatus
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Solution Overview
Problem
Traditional all-wheel drive (AWD) vehicles experience decreased fuel efficiency due to continuous rotation of secondary driveline components, even when not engaged, and existing disconnect apparatuses are inefficient in rapid connection and disconnection.
Innovation Solution
A driveline rapid disconnect apparatus featuring a cam cylinder with a ramp, first and second clutch elements, and a latching mechanism, allowing for efficient engagement and disengagement of driveline components, reducing energy loss and improving fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional disconnect apparatuses are used to disconnect driveline components, then fuel efficiency is improved by reducing continuous rotation of secondary drive axle, but connection and disconnection speed is insufficient
Solution Approach 1:
The cam cylinder is designed to rotate dynamically between 0-90 degrees to rapidly transition clutch elements between engaged and disengaged states. This dynamic rotation mechanism enables fast connection and disconnection of driveline components, directly addressing the speed limitation of traditional disconnect apparatuses while maintaining the energy-saving benefit of selective disconnection.
Solution Approach 2:
The latching mechanism with cam follower and radial depression is designed to pre-position and rapidly latch the cam cylinder at predetermined angular positions (0 degrees for disengaged, 90 degrees for engaged). This preliminary positioning action enables instantaneous transition between states, achieving both fast connection/disconnection and reliable engagement without energy loss during the transition process.
2Reliability
If a latching mechanism is added to maintain cam cylinder axial position, then reliability of connection is improved, but device complexity increases
Solution Approach 1:
The cam follower acts as an intermediary element that translates the rotation of the cam cylinder into axial movement of the clutch elements. The cam follower engages with the cam surface and radial depression, automatically maintaining the cam cylinder at predetermined axial positions corresponding to engaged and disengaged states. This intermediary mechanism provides reliable positioning without requiring complex external latching systems.
Solution Approach 2:
The latching mechanism is designed to be self-actuating through the interaction between the cam follower, cam surface, and radial depression. As the cam cylinder rotates, the cam follower automatically latches into the radial depression at predetermined positions, maintaining axial position without requiring additional actuators or complex control systems. The mechanism serves itself through its own geometric design.
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 apparatus enables rapid and efficient disconnection of driveline components, enhancing fuel economy by minimizing energy loss when AWD functionality is not required, while reducing noise, vibration, and harshness (NVH) through smooth operation.
Implementation Method 1
a cam cylinder including a ramp disposed in a radially outer surface thereof... A first clutch element is disposed at least partially inside the cam cylinder... The cam follower selectively disposed at least partially in the radial depression
Data Source
AI summary
An axle disconnect apparatus having a cam cylinder including a ramp disposed in a radially outer surface thereof. A first clutch element disposed at least partially inside the cam cylinder and an intermediate shaft disposed at least partially within the first clutch element. The intermediate shaft includes a splined portion in constant mesh with the first clutch element. A half shaft may be disposed coaxially with the intermediate shaft, and a second clutch element may be coupled with the half shaft. The first clutch element selectively engages the second clutch element. The axle disconnect apparatus further comprises a latching mechanism whereby the cam cylinder maintains an axial position. The latching mechanism including a radial depression in the cam cylinder ramp, and a cam follower selectively disposed at least partially in the radial depression.