Clutch Ring Disconnector Layout for Compact Quiet 4WD Switching
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Solution Overview
Problem
Existing disconnector apparatuses for switching between four-wheel drive and two-wheel drive result in increased vehicle length, weight, and noise due to complex operational structures and high differential issues, leading to vibration and poor mountability.
Innovation Solution
A disconnector apparatus featuring a clutch ring and support ring with engaging clutch parts, an actuator device, and a modularized design that eliminates unnecessary components, allowing for efficient switching between four-wheel drive and two-wheel drive modes while minimizing current consumption and reducing noise through differential restriction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the ball screw shaft, fork, and disconnector sleeve are operated in conjunction with one another by the operation of the motor, then four-wheel drive can be implemented, but the overall length and space of the vehicle excessively increase
Solution Approach 1:
The patent merges the disconnector shaft and disconnector hub connection functions into a simplified clutch mechanism where the clutch ring directly engages with the differential side gear. This eliminates the need for separate ball screw shaft, fork, and disconnector sleeve components, thereby reducing overall vehicle length while maintaining four-wheel drive capability.
Solution Approach 2:
The patent extracts and removes the complex intermediate transmission components (ball screw shaft, fork, disconnector sleeve) from the power transmission path. By directly coupling the clutch ring to the differential side gear, the design eliminates unnecessary components that contributed to excessive vehicle length.
2Adaptability or versatility
If the ball screw shaft, fork, and disconnector sleeve are operated in conjunction with one another by the operation of the motor, then four-wheel drive can be implemented, but the weight and mountability of the vehicle are adversely affected
Solution Approach 1:
The patent combines multiple functions into fewer components. The clutch ring serves both as a connection element and a differential engagement mechanism, eliminating the need for separate ball screw shaft, fork, and disconnector sleeve components. This component reduction directly decreases vehicle weight.
Solution Approach 2:
The patent removes unnecessary intermediate components (ball screw shaft, fork, disconnector sleeve) from the system. By extracting these redundant parts and implementing a direct clutch-to-differential connection, the overall vehicle weight is reduced while maintaining four-wheel drive functionality.
3Loss of energy
If the disconnector shaft and disconnector hub are disconnected to implement two-wheel drive, then power loss is minimized, but noise and vibration occur due to high differential
Solution Approach 1:
The patent introduces a clutch ring as an intermediary element that can selectively engage with the differential side gear. This mediator allows for controlled connection during two-wheel drive operation, preventing the high differential condition that causes noise and vibration while maintaining the ability to disconnect for power efficiency.
Solution Approach 2:
The patent implements a dynamic engagement mechanism where the clutch ring can be selectively connected or disconnected from the differential side gear based on driving conditions. This dynamic control allows the system to maintain connection during two-wheel drive to prevent high differential noise, while still enabling power loss minimization when needed.
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 solution significantly reduces vehicle length and weight, improves mountability, minimizes current consumption, and eliminates noise by allowing the support ring to rotate freely during two-wheel drive, enhancing assembly and repair efficiency while providing versatility in mounting.
Implementation Method 1
a ball screw shaft (230) connected to the motor (220)
Data Source
AI summary
Proposed is a disconnector apparatus including a casing having therein a support ring and one side gear, and a clutch ring having a first clutch part disposed on an inner-diameter portion of the clutch ring at one side of the clutch ring facing one side gear, and a second clutch part disposed on one inner surface of the inner-diameter portion, in which the first clutch part engages with a third clutch part disposed on an outer-diameter portion of the support ring at one side of the support ring, and the second clutch part engages with a fourth clutch part disposed on one surface of the one side gear.