Differential Disconnect Clutch With End Face Teeth for Compact Torque Transfer
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Solution Overview
Problem
Existing automobile differential systems face inefficiencies in torque transmission, are bulky, and are inconvenient to arrange due to reliance on friction for disengagement or engagement, particularly when switching between four-wheel and two-wheel drive modes.
Innovation Solution
A differential system with a disconnect mechanism using self-holding electromagnetic clutches and end face teeth for quick power disengagement or engagement, combined with a differential locking mechanism for synchronized or differential wheel rotation, allowing compact design and high torque efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If friction-based differential power disengagement/engagement is used, then the differential system can achieve power disconnection, but the torque transmission efficiency is low and the volume is large
Solution Approach 1:
The patent replaces the traditional friction-based mechanical disengagement system with an electromagnetic clutch system. The electromagnetic clutch uses electromagnetic fields to engage and disengage power transmission, eliminating the need for friction-based mechanisms. This substitution achieves high torque transmission efficiency during engagement while significantly reducing the overall system volume, as electromagnetic clutches are more compact than friction-based differential locks.
2Ease of operation
If friction-based differential power disengagement/engagement is used, then the differential system can achieve power disconnection, but the system is large in volume and not convenient to arrange in vehicle
Solution Approach 1:
The patent employs a nested structure where the electromagnetic clutch is integrated within the differential housing. The clutch assembly is positioned concentrically within the differential case, with the plate clutch components nested between the differential planets and the housing. This nesting arrangement maximizes space utilization and minimizes the overall volume of the differential system, making it more convenient for vehicle integration.
3Loss of energy
If electromagnetic clutch is used for power disengagement/engagement, then torque transmission efficiency is high and volume is compact, but the mechanism complexity increases
Solution Approach 1:
The electromagnetic clutch assembly performs multiple functions within a single integrated mechanism. It provides both the engagement and disengagement of power transmission, acts as a torque limiter, and serves as a compact space-saving component. The plate clutch structure simultaneously engages with both the differential planets and the housing, providing versatile control over power flow while maintaining relatively simple construction.
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
Enables rapid power disengagement or engagement with high torque transmission efficiency, compact structure, and improved controllability, reducing tire wear and power consumption while facilitating vehicle maneuverability.
Implementation Method 1
the disconnect clutch is connected with the first end face teeth, and is configured to drive the first end face teeth to move axially relative to the second end face teeth
Data Source
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AI summary
A differential system is disclosed, which comprises a differential and a differential disconnect mechanism. The differential comprises an outer differential housing (1) and an inner differential housing (2), and the outer differential housing (1) is used for transmission connection with an upper stage transmission structure of the differential. The differential disconnect mechanism comprises a disconnect clutch (40), first end face teeth (7) and second end face teeth (8). The first end face teeth (7) are disposed between the outer differential housing (1) and the inner differential housing (2) and are movably connected with the outer differential housing (1) so that the first end face teeth (7) can move axially and rotates synchronously relative to the outer differential housing (1). The second end face teeth (8) are fixedly connected with the inner differential housing (2). The disconnect clutch (40) is connected with the first end face teeth (7), and is configured to drive the first end face teeth (7) to move axially relative to the second end face teeth (8), and control the first end face teeth (7) and the second end face teeth (8) to engage or disengage. The differential system can quickly disengage or engage the power of the differential, and has the advantages of high torque transmission efficiency, long service life, compact structure, and being convenient to be arranged in the vehicle and so on.