Vehicle Disconnect Module With Cycloidal Reducer and Position Stop

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Solution Overview

Problem

Existing disconnect modules for electric vehicles have limitations such as large footprint, high cost, low position accuracy, and long response time, which hinder efficiency and performance.

Innovation Solution

A disconnect module with a cycloidal gear speed reducer integrated with a mechanical position-limiting mechanism, which allows for high position accuracy, short response time, and a compact design, thereby overcoming the limitations of prior art.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a planetary gear speed reducer is used, then high efficiency and strong robustness are achieved, but the footprint is large and the cost is high

Engineering Contradiction:

ImproverobustnessVSAvoidfootprint

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent replaces the traditional planetary gear speed reducer with a voice coil motor directly coupled to the connecting shaft. This substitution eliminates the mechanical gear train, thereby reducing the footprint and component count while maintaining the disconnection function through electromagnetic actuation rather than mechanical gearing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If a worm gear speed reducer is used, then high transmission ratio is achieved, but the response time is long and efficiency is low

Engineering Contradiction:

Improvetransmission ratioVSAvoidresponse time

Core Design Contradiction:

PowerVSLoss of time

Solution Approach 1:

The patent replaces the worm gear speed reducer with a voice coil motor that provides direct drive capability. This eliminates the mechanical transmission stages that cause response delays, enabling the disconnection mechanism to respond rapidly to control signals while achieving the required motion through direct electromagnetic force application to the connecting shaft.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Length of moving object

If a fork ball screw is used, then linear motion is achieved, but the radial packaging size is limited and engagement dynamics are affected

Engineering Contradiction:

Improvelinear motion capabilityVSAvoidradial packaging size

Core Design Contradiction:

Length of moving objectVSArea of stationary object

Solution Approach 1:

The patent replaces the fork ball screw mechanism with a voice coil motor that directly actuates the connecting shaft. This substitution eliminates the need for complex linear motion conversion mechanisms, reducing radial packaging size while maintaining the ability to achieve the required axial displacement for engagement and disconnection through direct electromagnetic actuation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Loss of energy

If a disconnection mechanism is added to reduce drag loss, then efficiency is improved, but the device complexity increases

Engineering Contradiction:

Improvedrag loss reductionVSAvoidmechanism complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical disconnection mechanisms with a voice coil motor system. This substitution reduces device complexity by eliminating multiple mechanical components (gears, ball screws, forks) while maintaining the disconnection function through a single electromagnetic actuator that directly controls the connecting shaft position.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 proposed solution achieves a smaller overall footprint, lower cost, and improved position accuracy, enabling faster response times and more efficient operation, particularly suitable for low-load applications in electric vehicles.

Implementation Method 1

a voice coil motor, which is configured to drive the connecting shaft to move

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentEP4520990A1Disconnect module, power transmission system for a vehicle, synchronization mechanism for a vehicle and vehicle technical field

Publication Date: 2025.03.12 VALEO EMBRAYAGES SAS

Figure 1
Figure 2A~2B
Figure 3A~3B

AI summary

The present invention relates to a disconnect module (10) for engaging and disengaging a first shaft (1) with and from a first component (2), the disconnect module comprising: a connecting shaft (11) arranged coaxially with the first shaft, one end of which is rotatably supported on the first shaft, and the other end of which is fixedly connected to the first component; a sliding sleeve (12) separately sleeved on outer sides of the first shaft and the connecting shaft, wherein the sliding sleeve is rotatably and fixedly connected to the first shaft and can reciprocate axially by an axial distance to engage with or disengage from the connecting shaft, and the sliding sleeve is provided with a circumferential groove open to the outside; a motor (13); a speed reducer (14) connected to the motor and comprising an output shaft; and a drive element (15) fixedly connected to the output shaft and extending into the circumferential groove to be driven by the speed reducer to rotate, thereby driving the sliding sleeve to reciprocate axially, and a mechanical position-limiting mechanism is provided on the output shaft, so that the output shaft can only rotate by a set angle corresponding to the axial distance.