Electromagnetic Differential Disconnect for Low-Wear Torque Transfer
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Solution Overview
Problem
Existing differential disconnect mechanisms in vehicles are inefficient in managing torque transfer and do not provide a seamless mechanism for disconnecting the drive gear from the gear set, leading to increased friction and wear.
Innovation Solution
A differential disconnect system featuring a clutch plate engaged by radial tabs and axial teeth, actuated by an electromagnet and clutch spring, allowing for controlled engagement and disengagement of the differential components to manage torque transfer efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a differential disconnect mechanism is used to manage torque transfer, then torque control between differentials is improved, but friction and wear increase during high-stress driving conditions
Solution Approach 1:
The clutch plate is extracted as a separate disconnectable element between the inner and outer differential housings. This allows the torque path to be selectively interrupted by removing the clutch plate from the engagement path, thereby eliminating friction and wear between the differential components during high-stress conditions while maintaining torque control capability when engaged
Solution Approach 2:
The differential disconnect mechanism transitions from a static connected state to a dynamic disconnectable state. The clutch plate can be engaged to transfer torque or disengaged to eliminate friction, providing dynamic adaptability. This is achieved through the movable clutch plate design that can be positioned in or out of the engagement path between inner and outer differential housings
2Power
If a clutch plate with axial teeth is used for torque transfer, then torque transmission efficiency is improved, but the complexity of the engagement mechanism increases
Solution Approach 1:
The complex mechanical engagement mechanism is replaced with an electromagnetic actuation system. The electromagnet converts electrical energy to mechanical motion to engage or disengage the clutch plate, eliminating the need for complex mechanical linkages, springs, or cam mechanisms while maintaining reliable torque transmission when engaged
Solution Approach 2:
The electromagnet serves multiple functions: it acts as both the actuator for engagement and the control element for disengagement. This single component replaces what would traditionally require multiple mechanical parts (springs, levers, latches), reducing overall mechanism complexity while maintaining torque transmission efficiency through the toothed clutch plate design
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 efficient torque transfer during normal driving and seamless disconnection of the drive gear from the gear set, reducing friction and wear, thereby enhancing vehicle performance and durability.
Implementation Method 1
the electromagnet is energized
Implementation Method 2
the armature is axially movable towards the electromagnet when the electromagnet is energized
Implementation Method 3
The clutch spring is arranged to urge the clutch plate towards the inner differential housing to engage the second plurality of axial teeth with the first plurality of axial teeth
Implementation Method 4
the clutch spring is a wave spring
Data Source
AI summary
A differential disconnect system includes an outer differential housing, an inner differential housing, a clutch plate arranged axially adjacent to the inner differential housing, a clutch spring, and an electromagnet. The outer differential housing has a first plurality of radial notches, the inner differential housing has a first plurality of axial teeth, and the clutch plate has a first plurality of radial tabs engaged with the first plurality of radial notches and a second plurality of axial teeth arranged to selectively engage the first plurality of axial teeth. The clutch spring is arranged to urge the clutch plate towards the inner differential housing to engage the second plurality of axial teeth with the first plurality of axial teeth. The clutch plate is urged away from the inner differential housing to disengage the second plurality of axial teeth from the first plurality of axial teeth when the electromagnet is energized.