Disconnect Clutch Shift Fork Sensing for Precise Pivot Control
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Solution Overview
Problem
Existing disconnect clutch actuator mechanisms lack efficient mechanisms for precise control and feedback in pivot position sensing, leading to potential misalignment and reduced performance in applications like differential systems.
Innovation Solution
A disconnect clutch actuator mechanism incorporating a shift fork with a rack gear, pinion gear, and position sensor, where the shift fork is pivotable on pins, and the position sensor senses the pivot position, enabling precise control and feedback through an electric motor and gear train, with engagement tabs for actuator ring displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a position sensor is added to sense pivot position, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The position sensor is integrated into the actuator housing structure, merging the sensing function with the existing mechanical housing. This reduces overall device complexity by eliminating separate mounting structures and integrating the sensor as part of the housing assembly rather than adding it as a completely separate component.
Solution Approach 2:
A sensor target is introduced as an intermediary element that is directly coupled to the shift fork. This target provides a reference for the position sensor to accurately measure pivot position without requiring the sensor to directly interface with moving parts, thereby improving measurement precision while maintaining structural simplicity.
2Reliability
If engagement tabs are added to displace actuator ring, then reliability is improved, but device complexity increases
Solution Approach 1:
The engagement tabs are integrated directly into the shift fork structure, merging the engagement function with the existing shift fork component. This eliminates the need for separate engagement mechanisms and reduces overall device complexity while maintaining reliable engagement with the actuator ring.
Solution Approach 2:
The engagement mechanism is segmented into discrete tabs on the shift fork that independently engage with corresponding features on the actuator ring. This segmentation allows for reliable engagement through multiple contact points while keeping each individual tab simple in structure, avoiding the need for complex engagement mechanisms.
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 provides precise control and feedback, ensuring accurate pivot position sensing and improved performance in differential systems by maintaining engagement between the rack and pinion gears, and allowing for adjustments based on detected pivot positions.
Implementation Method 1
The actuator includes a pinion gear engaged with the rack gear. The actuator is arranged to pivot the shift fork.
Implementation Method 2
The position sensor is arranged proximate the sensor target for sensing a pivot position of the shift fork.
Implementation Method 3
the actuator also includes an electric motor and a gear train for rotating the pinion gear
Data Source
AI summary
A disconnect clutch actuator mechanism includes a shift fork, an actuator, and a position sensor. The shift fork includes a rack gear, a pair of pins, and a sensor target. The shift fork is arranged to be pivotable on the pair of pins. The actuator includes a pinion gear engaged with the rack gear. The actuator is arranged to pivot the shift fork. The position sensor is arranged proximate the sensor target for sensing a pivot position of the shift fork. In some example embodiments, the rack gear includes a pair of arched portions and a toothed portion disposed on at least one of the pair of arched portions. The pinion gear is engaged with the toothed portion. In an example embodiment, the rack gear has a gap disposed between the pair of arched portions and the pinion gear is disposed in the gap.