Compact Axle Module With Nested Clutch Packs
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Solution Overview
Problem
Existing dual electronically controlled torque distribution systems in automotive vehicles are bulky, making them difficult to package within a vehicle's limited space, leading to increased cross-vehicle width, which compromises packaging efficiency and durability, and hinders the adoption of all-wheel drive technology across vehicle lines.
Innovation Solution
An axle module design that integrates two electronically controlled axle shafts into a compact package using a ring gear assembly with nested bearings and a hub structure that defines separate cavities for clutch packs, reducing packaging width and allowing independent control of torque distribution between wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If two separate electronic control systems with clutch packs are used for torque distribution, then independent control of torque distribution between wheels is achieved, but the system width increases making packaging difficult
Solution Approach 1:
The patent combines two separate electronic control systems into a single integrated control system that manages both clutch packs. The housing contains both clutch assemblies (first clutch pack with first plurality of friction plates, second clutch pack with second plurality of friction plates) and their respective activation mechanisms within a unified structure, eliminating the need for separate control systems while maintaining independent torque distribution capability.
Solution Approach 2:
The patent employs nested arrangement where the first and second clutch packs are positioned one within or alongside the other in a compact configuration. The first inner hub and second inner hub are arranged concentrically or adjacently within the housing, with their respective clutch packs nested to minimize the overall width of the assembly while preserving independent activation capability.
2Ease of operation
If increased cross-vehicle width is accommodated for dual electronic control systems, then torque distribution control is maintained, but packaging conflicts with chassis components occur
Solution Approach 1:
The patent merges the two electronic control systems into a single integrated unit with a common housing that contains both clutch packs and their activation mechanisms. This consolidation reduces the overall volume and packaging space required compared to having two separate control systems, while maintaining the capability for independent torque distribution control to each wheel.
3Area of stationary object
If inboard side shaft joints are positioned towards the wheel to accommodate system width, then packaging is adjusted, but joint angles increase decreasing efficiency and durability
Solution Approach 1:
The patent uses a nested arrangement of the clutch packs and inner hubs that reduces the overall width of the torque distribution system. This compact nested configuration allows the inboard side shaft joints to be positioned closer to the center of the vehicle rather than towards the wheels, thereby reducing joint angles and improving constant velocity joint efficiency and durability while maintaining appropriate packaging.
Data Source
AI summary
An axle module may comprise an outer housing and a ring gear assembly rotatably supported within the outer housing on a hub. The axle module may further include first and second shafts arranged within the ring gear assembly, and first and second inner hubs rotatably fixed to the first and second shafts, respectively. Additionally, the axle module may include first and second clutch packs, each having a first plurality of friction plates fixed for rotation to the first and second inner hubs, and a second plurality of friction plates fixed for rotation to the hub. Exemplary axle modules may have a reduced packaging width.