Drive Axle Collar Actuator Using Electromagnetic Coil
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing drive axle assemblies require large differential actuator mechanisms, which are not suitable for compact designs, limiting their application in various vehicle configurations.
Innovation Solution
A drive axle assembly with a collar actuator mechanism that includes an electromagnetic coil and a biasing member, allowing the collar to be actuated between engaged and disengaged positions using magnetic forces, reducing the need for bulky mechanical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional mechanical actuator mechanism is used to actuate the collar, then the collar can be moved between engaged and disengaged positions, but the actuator mechanism becomes large and bulky, making it unsuitable for compact drive axle assemblies
Solution Approach 1:
The patent replaces the traditional mechanical actuator mechanism with an electromagnetic coil that uses magnetic fields to actuate the collar. The electromagnetic coil generates a magnetic force that moves the collar between engaged and disengaged positions without requiring complex mechanical linkages, thereby reducing the size and volume of the actuator mechanism while maintaining reliable collar actuation.
Solution Approach 2:
The patent changes the actuation mechanism from mechanical to electromagnetic by utilizing magnetic field parameters. The electromagnetic coil converts electrical energy into magnetic force, which directly acts on the collar to produce motion. This parameter change enables a more compact design while achieving the same functional outcome of collar actuation.
2Reliability
If a large differential actuator mechanism is used, then the collar can be reliably actuated, but the overall drive axle assembly size increases and weight increases
Solution Approach 1:
The patent substitutes heavy mechanical actuator components with a lighter electromagnetic coil assembly. The electromagnetic coil generates sufficient magnetic force to actuate the collar without requiring the bulky mechanical linkages, levers, and actuators that would increase weight. This substitution maintains reliable collar actuation while significantly reducing the overall weight of the drive axle assembly.
3Volume of moving object
If a compact electromagnetic coil design is used to reduce size, then the actuator mechanism becomes smaller, but the magnetic force may be insufficient to overcome the biasing member force
Solution Approach 1:
The patent optimizes the electromagnetic coil parameters including wire gauge, number of turns, and current density to generate sufficient magnetic force within a compact volume. By carefully adjusting these parameters, the coil produces enough magnetic attractive force to overcome the biasing member force and reliably actuate the collar, while maintaining a small size that fits within the drive axle assembly constraints.
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 enables a compact drive axle assembly that effectively transmits torque while reducing weight and cost, suitable for a range of vehicle applications by using an electromagnetic coil to actuate the collar between engaged and disengaged positions.
Implementation Method 1
a magnetic attractive force exerted by the electromagnetic coil overcomes the biasing force exerted by the biasing member to actuate the collar from the first position to the second position
Implementation Method 2
The biasing member is disposed between the input shaft and the electromagnetic coil and exerts a biasing force that biases the collar away from the first gear
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A drive axle assembly having a collar actuator mechanism that may include an electromagnetic coil. The electromagnetic coil may be disposed in a stationary position with respect to a housing and may be configured to actuate the collar.