CV Joint Disconnect Assembly With Electromechanical Engagement
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Solution Overview
Problem
Existing wheel-end disconnect assemblies for vehicles are complex and costly due to their intricate components, making them difficult to manufacture and maintain.
Innovation Solution
A continuous velocity joint assembly with a disconnect capability, featuring a rotatable input and output, a disconnect arrangement with relative rotation capabilities, and an electromechanical actuator to shift between connected and disconnected states, ensuring power transfer only in the connected state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If automated systems are used to engage and disengage drivetrain from wheels, then ease of operation is improved, but device complexity increases due to numerous intricate components
Solution Approach 1:
The disconnect assembly is divided into separate functional components: a disconnect collar, clutch plates, actuator, and spring mechanism. Each component performs a specific function, allowing the complex automated engagement/disengagement task to be broken down into manageable segments that work together systematically
Solution Approach 2:
The spring mechanism automatically engages the clutch plates when the actuator retracts, and the detent mechanism automatically locks the disconnect collar in position. This self-service capability reduces the need for complex control systems while maintaining automated operation, as the mechanical components themselves perform the engagement and locking functions
2Reliability
If numerous intricate components are used in disconnect mechanisms, then reliability may be improved through redundancy, but manufacturing cost and maintenance difficulty increase
Solution Approach 1:
Multiple functions are merged into single components: the disconnect collar simultaneously transmits torque and controls engagement/disengagement, while the spring and detent mechanisms work together in a compact integrated assembly. This merging reduces the total number of parts that need to be manufactured and assembled, lowering production costs and simplifying maintenance
Solution Approach 2:
The disconnect collar serves multiple functions: it transmits rotational force from the driveshaft, controls the engagement of clutch plates, and interfaces with the actuator mechanism. This multi-functionality reduces the need for separate dedicated components, simplifying the overall assembly while maintaining reliability
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 simplifies the wheel-end disconnect assembly by reducing the number of components, lowering manufacturing and maintenance costs, while maintaining efficient power transfer and ensuring reliable operation even when power is lost.
Implementation Method 1
An electromechanical actuator causes the disconnect arrangement to shift between the disconnected state and the connected state
Implementation Method 2
the energy storage element may comprise a torsion spring (e.g., a clock spring) to rotate the lead screw via stored energy
Data Source
AI summary
A continuous velocity joint assembly comprising a rotatable input and a rotatable output. A continuous velocity mechanism that allows transfer of power between the input and the output while allowing angular variation is also provided. A disconnect arrangement has first and second portions capable of relative rotation with respect to one another in a disconnected state and incapable of relative rotation with respect to one another in a connected state. An electromechanical actuator causes the disconnect arrangement to shift between the disconnected state and the connected state, whereby the power is transferred between the input and the output in the connected state and power is not transferred between the input and the output in the disconnected state.