Vehicle Differential Disconnect Assembly Torque Distribution
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Solution Overview
Problem
Traditional torque transfer systems in all-wheel drive vehicles require significant space and complexity due to separate units for torque distribution between axles, limiting flexibility and efficiency.
Innovation Solution
A vehicle differential disconnect assembly with a differential case, gear set, and torque distribution device, featuring a clutch pack and actuator assembly, where the clutch pack is located on one side of the differential case and the actuator assembly on the other, with a mover transmitting movement across the differential gear set to manage torque distribution efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional torque transfer coupling is used between primary and secondary driven axles, then torque distribution between axles is achieved, but the system requires significant space for separate housing and related parts
Solution Approach 1:
The patent combines the torque transfer coupling and differential assembly into a single integrated unit. The torque transfer coupling is positioned within the differential housing, eliminating the need for separate housing and reducing overall space requirements while maintaining torque distribution capability between axles
2Adaptability or versatility
If a traditional torque transfer coupling with separate unit configuration is used, then torque distribution is achieved, but the device complexity increases due to multiple separate components
Solution Approach 1:
The invention merges the torque transfer coupling with the differential assembly into one integrated unit, reducing the number of separate components and simplifying the overall drivetrain architecture while preserving torque distribution functionality
Solution Approach 2:
The differential housing serves multiple functions: it houses the differential gear set and simultaneously accommodates the torque transfer coupling mechanism, making the assembly multi-functional and reducing overall system complexity
3Device complexity
If the clutch pack and actuator assembly are located on the same side of the differential case, then the configuration is simple, but the mover cannot effectively span across the differential gear set to transmit movement
Solution Approach 1:
The invention positions the clutch pack and actuator assembly on opposite sides of the differential case, utilizing the axial dimension to span across the differential gear set. This dimensional arrangement allows the mover to effectively transmit movement through the gear set, improving torque transmission efficiency
Data Source
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AI summary
A vehicle differential disconnect assembly can include a differential case, a differential gear set, and a torque distribution device. The differential gear set is carried within the differential case. The torque distribution device transfers torque between the differential gear set and side shafts of the accompanying vehicle driveline. The torque distribution device can include a clutch pack and an actuator assembly. The clutch pack is located at a first side of the differential case relative to the differential gear set, and the actuator assembly is located at a second side of the differential case relative to the differential gear set. The actuator assembly has a mover that transmits movement to the clutch pack when the actuator assembly actuates and deactuates the clutch pack.