Disconnect Apparatus Cam Mechanism Position Sensing
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Solution Overview
Problem
Current disconnect apparatuses for all-wheel drive vehicles face challenges in enhancing efficiency and manufacturability while minimizing cost and weight, and existing solutions do not effectively address the need for precise sensing and actuation of the disconnect mechanism.
Innovation Solution
A disconnect apparatus featuring a housing with first and second clutch members, a cam mechanism with axially movable and rotatable cam members, and a sensor assembly using Hall-effect sensors to determine the position of the cam mechanism, allowing for efficient engagement and disengagement of driveline components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a disconnect apparatus is used to selectively connect driveline components, then fuel efficiency is improved, but device complexity increases
Solution Approach 1:
The patent employs nested clutch members where the first clutch member is disposed within the housing and the second clutch member is in selective engagement with the first clutch member. This nested arrangement allows multiple clutching functions to be integrated within a compact structure, reducing overall device complexity while maintaining the ability to selectively connect driveline components for improved fuel efficiency.
Solution Approach 2:
The cam mechanism serves multiple functions: it actuates the clutch members for engagement/disengagement, provides mechanical advantage for force multiplication, and enables selective connection of driveline components. By consolidating these functions into a single mechanism, the patent reduces the number of separate components needed, thereby reducing device complexity while maintaining fuel efficiency benefits.
2Reliability
If a cam mechanism is used to actuate the disconnect apparatus, then actuation reliability is improved, but manufacturing cost increases
Solution Approach 1:
The cam mechanism is divided into separate components: a first cam member and a second cam member. This segmentation allows each cam member to be manufactured independently using standard machining processes, reducing overall manufacturing cost. The modular design maintains actuation reliability by ensuring each segment performs its specific function correctly while working in conjunction with the other.
3Measurement precision
If Hall-effect sensors are used to sense cam mechanism position, then measurement precision is improved, but device weight increases
Solution Approach 1:
The patent replaces mechanical position sensing methods with Hall-effect sensors, which are electronic sensors that detect the position of the cam mechanism based on magnetic field changes. This substitution provides precise position measurement without requiring heavy mechanical linkages or complex mechanical sensing mechanisms, thereby improving measurement precision while minimizing the increase in device weight.
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 enhances the efficiency and manufacturability of the disconnect apparatus, enabling precise control and reduced cost and weight, while ensuring reliable operation and improved fuel economy by accurately sensing and actuating the disconnect mechanism.
Implementation Method 1
A sensor assembly using Hall-effect sensors to determine the position of the cam mechanism
Data Source
AI summary
A disconnect apparatus including a first clutch member and a second clutch member in selective engagement with the first clutch member. The disconnect apparatus also includes a cam mechanism and a sensor assembly. The cam mechanism includes an axially movable first cam member and an axially fixed second cam member. Wherein the sensor assembly generates a pulse pattern which is utilized to determine a position of the first cam member, and thereby a state of the disconnect apparatus.