Selective Driveline Coupling Assembly for On-Demand Torque Transfer
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Solution Overview
Problem
Existing automotive drivelines lack efficient mechanisms for selectively connecting and disconnecting components to optimize torque transmission based on vehicle operational modes, leading to unnecessary energy consumption and inefficiencies.
Innovation Solution
A driveline component with a selective connection assembly featuring a drive cam and follower cam system, controlled by an actuator, allows for the controlled engagement and disengagement of rotary components, such as shafts, using sloped cam surfaces to axially move a coupling body, enabling seamless transitions between connected and disconnected states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If driveline components are permanently connected to ensure continuous torque transmission capability, then reliability of torque transmission is improved, but energy loss increases due to parasitic drag on disconnected components
Solution Approach 1:
The patent applies the dynamics principle by implementing a selective connection assembly that can dynamically change the connection state between driveline components based on operating conditions. The assembly includes a coupling body with splines that can be selectively engaged or disengaged from shaft splines, allowing the system to transition between connected and disconnected states. This dynamic adaptability ensures torque transmission reliability when needed while eliminating parasitic drag when components are not required, thereby resolving the contradiction between reliability and energy loss.
2Loss of energy
If driveline components are selectively disconnected to reduce energy loss, then energy efficiency is improved, but device complexity increases due to additional connection mechanisms
Solution Approach 1:
The patent applies segmentation by dividing the driveline system into separable components with a selective connection assembly. The assembly is segmented into a coupling body with internal splines and shafts with external splines, allowing independent engagement and disengagement. This segmentation enables the system to disconnect components to reduce energy loss while maintaining a relatively simple overall structure, as each segment can be independently controlled without requiring complex reconfiguration of the entire driveline.
Solution Approach 2:
The coupling body acts as an intermediary element between the shafts, providing a simple mechanical interface for selective connection and disconnection. Rather than requiring complex control mechanisms directly on each shaft, the intermediary coupling body with splines provides a centralized, simple mechanism that can engage or disengage multiple shafts simultaneously, thereby reducing overall device complexity while enabling energy-efficient selective disconnection.
3Adaptability or versatility
If clutch mechanisms are used to selectively engage driveline components, then adaptability to different driving modes is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces traditional clutch mechanisms with a spline-based selective connection assembly. Instead of using friction-based clutch plates and complex actuation systems, the invention uses splines that provide direct mechanical engagement and disengagement through axial movement. This substitution maintains adaptability to different driving modes (such as two-wheel drive and four-wheel drive) while significantly reducing device complexity and manufacturing cost, as the spline interface is simpler to manufacture and control than traditional clutch systems.
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
Enables dynamic torque transmission by allowing components to be coupled or decoupled as needed, enhancing energy efficiency and operational flexibility in vehicles with on-demand all-wheel drive configurations.
Implementation Method 1
The drive cam is rotated about an axis by the actuator, has a first drive surface at a non-zero angle to the axis, and a second drive surface at a non-zero angle to the axis. The follower cam has a first driven surface and a second driven surface, and the follower cam is arranged to move axially to axially move the coupling body.
Data Source
AI summary
A driveline component with a selective connection assembly includes a first rotary component having splines, a second rotary component having splines, a coupling body arranged to be mated with the first rotary component splines and the second rotary component splines, an actuator, a drive cam and a follower cam. The drive cam is rotated about an axis by the actuator, has first and second drive surfaces both at a non-zero angle to the axis. The follower cam has first and second driven surfaces, and moves axially to move the coupling body. Rotation of the drive cam in a first direction engages the first drive and driven surfaces which moves the follower cam and coupling body in a first axial direction. Rotation of the drive cam in a second direction engages the second drive and driven surfaces which moves the follower cam and coupling body in a second axial direction.