Disconnectable Axle Assembly with Planetary Differential
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Solution Overview
Problem
Modern automotive vehicles with all-wheel drive or four-wheel drive drivelines require a compact, robust, and cost-effective disconnect mechanism for the axle assembly that enhances traction and fuel economy, but existing solutions are not optimized for reduced size and mass.
Innovation Solution
The axle assembly incorporates a housing assembly with an input pinion, ring gear, differential assembly, and a clutch system featuring a coupling member with external and internal teeth, a spring bias, and a linear motor for selective engagement, allowing for compact design and efficient power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a disconnect mechanism is added to enhance traction and fuel economy, then driveline functionality is improved, but device complexity increases
Solution Approach 1:
The disconnect mechanism is merged with the differential assembly by integrating the clutch directly into the differential housing. The clutch assembly includes a clutch drum, clutch plates, and springs that are combined with the differential components, allowing the disconnect function to be performed without adding a separate complex disconnect mechanism. This merging reduces overall device complexity while maintaining enhanced driveline functionality.
Solution Approach 2:
The differential housing serves multiple functions: it houses the differential mechanism, contains the disconnect clutch assembly, and provides mounting for bearings and gears. The clutch assembly itself performs both the disconnect function and transmits power when engaged. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while maintaining adaptability.
2Weight of moving object
If the axle assembly is made more compact to reduce size and mass, then vehicle efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The clutch assembly is nested within the differential housing, with the clutch drum positioned inside the differential assembly. The clutch plates are nested between the clutch drum and the differential case. This nested arrangement allows multiple components to occupy the same spatial envelope, reducing the overall size and mass of the axle assembly while maintaining proper component alignment through the hierarchical nesting structure.
Solution Approach 2:
The planet gears are arranged in a three-dimensional configuration around the sun gear, utilizing radial and axial dimensions to achieve compact packaging. The clutch components are arranged axially within the differential housing, using the axial dimension to stack components efficiently. This multi-dimensional arrangement reduces the overall footprint and mass of the assembly while maintaining manufacturing precision through standardized component interfaces.
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
This configuration enables a compact, robust, and cost-effective disconnect mechanism that optimizes traction and fuel economy by allowing selective coupling of output members, reducing size and mass while maintaining efficient power transmission.
Implementation Method 1
a linear motor for selective engagement
Implementation Method 2
a spring bias
Data Source
Figure 1
Figure 2
AI summary
A disconnecting axle assembly with a planetary differential assembly and a coupling that selectively couples a planet carrier of the planetary differential assembly to an axle shaft.