Dual Axle Disconnect Assembly Single Actuator
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Solution Overview
Problem
Current systems for vehicles with two prime movers and separate drive trains require separate assemblies and actuators for each drive train to connect and disconnect drive gears and axles, leading to increased complexity and cost.
Innovation Solution
A dual axle disconnect assembly utilizing a single actuator and threaded selector to transition between drive and disconnect modes by displacing annular sleeves and threaded nuts within housings, enabling relative rotation between drive gears and axles, thus eliminating the need for separate disconnect mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate assemblies and actuators are used for each drive train, then reliable connection and disconnection of drive gears and axles is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines two separate disconnect assemblies into a single integrated assembly that controls both drive axles. The single assembly includes a selector mechanism with threaded selector that simultaneously controls first and second annular sleeves, which in turn control the connection state of both drive axles. This merging reduces the number of actuators from two to one, simplifying the overall system while maintaining reliable connection and disconnection functionality for both drive trains.
Solution Approach 2:
The single disconnect assembly performs multiple functions by using one actuator to control both drive axles. The threaded selector mechanism can independently position the first and second annular sleeves to connect or disconnect either or both drive axles, providing universal control capability that replaces the need for separate dedicated assemblies for each axle.
2Adaptability or versatility
If separate assemblies and actuators are used for each drive train, then independent control of each drive train is achieved, but cost increases
Solution Approach 1:
The patent merges two separate control systems into one integrated disconnect assembly. The single assembly uses a shared housing, selector mechanism, and actuator to control both drive axles, reducing the total number of components that need to be manufactured and assembled. This consolidation lowers material costs, assembly costs, and maintenance costs while preserving the ability to independently control each drive train through the selector's positioning capabilities.
3Device complexity
If a single actuator is used to control both drive axles, then device complexity and cost are reduced, but control precision may be compromised
Solution Approach 1:
The selector mechanism is segmented into multiple independent control elements within a single assembly. The threaded selector includes separate threaded portions that engage with first and second annular sleeves independently, allowing each sleeve to be positioned precisely at different axial locations. This segmentation enables independent control of each drive axle while using a single actuator, maintaining control precision without requiring two separate actuators.
Solution Approach 2:
The patent introduces annular sleeves as intermediary elements between the selector mechanism and the drive axles. These sleeves act as mediators that translate the rotational and axial motion of the single threaded selector into precise positioning actions for both drive axles. The intermediaries ensure that control precision is maintained for each axle independently, even though they are controlled by a single actuator through the shared selector mechanism.
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 solution simplifies the disconnect process, reduces the footprint and cost of disconnect mechanisms, and provides a unified method for disconnecting dual axles from drive gears, enhancing operational efficiency and reducing complexity.
Implementation Method 1
a threaded selector; a first clutch including a first annular sleeve and a first threaded nut, the first threaded nut connected to the first annular sleeve, meshed with the threaded selector
Data Source
AI summary
A disconnect assembly, including: a selector; a first clutch including a first sleeve; and a second clutch including a second sleeve. In a drive mode, the first sleeve non-rotatably connects a first drive gear and a first axle of a first drive train, and the second sleeve is non-rotatably connects a second drive gear to a second axle of a second drive train. In a disconnect mode, relative rotation between the first drive gear and the first axle is enabled and relative rotation between the second drive gear and the second axle is enabled. To transition from the drive mode to the disconnect mode, the selector is displaced by an actuator, the selector is arranged to disconnect the first annular sleeve from the first drive gear or the first axle, and the selector is arranged to disconnect the second annular sleeve from the second drive gear or the second axle.