Compact eAxle Differential Clutch Assembly Without Axial Growth
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Solution Overview
Problem
The integration of additional functions, such as mechanically intermitting torque transmission, to an eAxle results in axial elongation, requiring design changes to the vehicle body and affecting ride quality, due to the inherent axial length and lateral width of eAxles.
Innovation Solution
A sub-assembly that includes an actuator, cam mechanism, and clutch assembly to limit differential motion, which is compactly integrated with the eAxle without increasing its axial size, allowing for seamless integration and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional functions (clutch and actuator) are incorporated into the eAxle to mechanically intermit torque transmission, then the torque transmission control is improved, but the axial length of the eAxle increases requiring vehicle body design changes
Solution Approach 1:
The clutch assembly and actuator are nested within the existing eAxle housing structure. The clutch assembly includes a first drum separably coupling with the differential and a second drum separably coupling with a side gear, with the actuator positioned to operate the clutch mechanism within the same axial space, thereby adding torque intermission functionality without increasing the overall axial length of the eAxle
2Adaptability or versatility
If the eAxle is made axially longer to accommodate additional devices, then the functional versatility is improved, but the lateral width increases affecting vehicle body design and ride quality
Solution Approach 1:
Instead of extending the eAxle axially or laterally, the invention utilizes the radial dimension by positioning the clutch assembly and actuator within the existing axial boundaries. The clutch assembly is arranged with drums coupling to differential components, and the actuator operates within the same axial envelope, effectively adding functionality in a compact three-dimensional arrangement that does not increase lateral width
3Device complexity
If devices are added to the exterior of the eAxle to avoid internal integration, then the eAxle internal structure is simplified, but vehicle body design changes are still required and support structure complexity increases
Solution Approach 1:
The clutch assembly and actuator are merged with the existing eAxle components. The clutch assembly includes drums that separably couple with differential elements, and the actuator is integrated to operate the clutch mechanism. This unified integration eliminates the need for separate support structures and exterior mounting, reducing overall system complexity while maintaining functional versatility
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 sub-assembly effectively limits differential motion without enlarging the eAxle, maintaining vehicle design integrity and ride quality, facilitating assembly and maintenance without requiring vehicle body modifications.
Implementation Method 1
a cam mechanism converting the rotational force into a thrust force in a direction of the axis
Implementation Method 2
a clutch assembly including a first drum separably coupling with the differential, and a second drum separably coupling with a side gear of the differential, the clutch assembly disposed so adjacent to the cam mechanism as to receive the thrust force to bring the friction clutch into action
Data Source
AI summary
A sub-assembly for limiting differential motion to an eAxle with a differential for differentially outputting torque about an axis is provided. An actuator is configured to generate a rotational force about the axis. A cam mechanism is configured to convert the rotational force into a thrust force in a direction of the axis. A clutch assembly includes a first drum separably coupling with the differential, and a second drum separably coupling with a side gear of the differential, The clutch assembly is disposed adjacent to the cam mechanism so as to receive the thrust force to bring a friction clutch into action. A cover is configured to enclose the cam mechanism and the clutch assembly and couple with the eAxle to support any one of the cam mechanism and the clutch assembly against the thrust force.