Vehicle Differential Disconnect Member for Gear Churning Loss Reduction
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Solution Overview
Problem
In all-wheel drive vehicles, existing differential assemblies continue to rotate and cause gear churning losses and wear when disconnecting wheels from the engine, leading to inefficiencies in fuel consumption and component wear.
Innovation Solution
A differential assembly with a disconnect member that includes a torque transmitting mechanism, allowing the ring gear to be selectively coupled and uncoupled from the differential case, preventing unnecessary rotation and torque transmission when not required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a disconnect member is coupled to the front differential assembly to separate the wheel axles from the differential and axle assembly, then torque transmission to the wheels is removed, but the differential gearing continues to rotate causing gear churning losses and wear
Solution Approach 1:
The patent extracts the torque transmitting function from the differential assembly by introducing a disconnect member that can be selectively engaged or disengaged. When disconnected, the torque transmitting member separates the ring gear from the differential case, preventing power transmission while stopping the differential gearing from rotating and eliminating gear churning losses.
Solution Approach 2:
The disconnect member acts as an intermediary component between the ring gear and the differential case. This intermediary element (comprising a torque transmitting member and a torque reacting member) allows selective control of torque transmission, enabling the system to switch between connected and disconnected states to prevent unnecessary gear rotation and energy loss.
2Use of energy by moving object
If the disconnect member is actuated to separate wheel axles from the differential assembly, then fuel efficiency improves, but unnecessary rotation of differential gearing causes component wear
Solution Approach 1:
The patent extracts the harmful rotational motion from the differential gearing by using the disconnect member to separate the torque transmission path. When the disconnect member is disengaged, the differential case and internal gearing are isolated from the ring gear, preventing rotation and eliminating wear while maintaining fuel efficiency benefits.
Solution Approach 2:
The disconnect member serves as a protective intermediary that prevents direct torque transmission when not needed. By positioning the torque transmitting member between the ring gear and differential case, it acts as a protective barrier that stops unnecessary gear rotation, thereby protecting components from wear while preserving fuel efficiency.
3Power
If the ring gear remains rotationally coupled to the differential case, then torque can be transmitted to the wheels, but gear churning losses occur when wheels are disconnected from the engine
Solution Approach 1:
The patent applies dynamics by making the connection between the ring gear and differential case selectable rather than fixed. The disconnect member enables the system to dynamically switch between two states: connected (for torque transmission) and disconnected (for preventing gear churning losses), allowing optimal performance based on operating conditions.
Solution Approach 2:
The patent extracts the harmful continuous rotation of the differential gearing by using the disconnect member to remove the torque transmission path when wheels are disconnected. This selective extraction of the torque path prevents energy loss through gear churning while maintaining the ability to transmit torque when needed.
Data Source
AI summary
A vehicle differential assembly is provided. The differential assembly including a differential case rotationally coupled to a differential housing. A differential gear set is rotationally coupled to the differential case. A ring gear rotationally coupled to the differential case. A disconnect member operably coupled between the ring gear and the differential case. The disconnect member having a torque transmitting member movable between a coupled and an uncoupled position, wherein the ring gear is rotationally coupled to the differential case when the torque transmitting member is in the coupled position.