Electromagnetic Pulse Disconnect Assembly for Drivetrain
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Solution Overview
Problem
Vacuum-powered powertrain disconnect systems in vehicles face issues due to varying vacuum levels caused by altitude and temperature changes, and are becoming less desirable with advanced vehicle designs, necessitating a reliable alternative for engaging and disengaging drivetrain components.
Innovation Solution
An electromagnetic pulse disconnect assembly powered by discrete electrical pulses, using an electromagnetic coil to generate axial force through an armature cam assembly with bi-directional ramps, allowing for compact and efficient switching between drivetrain modes without relying on vacuum power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum-powered disconnect systems are used, then drivetrain components can be engaged and disengaged, but the system reliability deteriorates due to varying vacuum levels caused by altitude and temperature changes
Solution Approach 1:
The patent replaces the vacuum-powered mechanical disconnect system with an electromagnetic disconnect system. The electromagnetic coil generates magnetic force to move the armature and cam assembly, eliminating dependence on vacuum levels. This substitution of electromagnetic actuation for vacuum actuation resolves the reliability issue caused by varying vacuum conditions across different altitudes and temperatures.
Solution Approach 2:
The patent changes the actuation parameter from vacuum pressure to electrical current. By using an electromagnetic coil that responds to electrical signals, the system achieves consistent performance regardless of atmospheric conditions. The electromagnetic force generated is directly controllable through current magnitude, providing stable operation across varying environmental parameters.
2Reliability
If continuous current is used to power the electromagnetic coil, then the disconnect assembly can operate reliably, but power consumption increases
Solution Approach 1:
The patent employs periodic or pulsed electrical current to the electromagnetic coil rather than continuous current. The coil is energized only during the transition periods when mode switching is required, and de-energized during steady-state operation. This periodic actuation maintains reliable disconnect functionality while dramatically reducing overall power consumption compared to continuous current supply.
Solution Approach 2:
The disconnect assembly incorporates self-latching or self-holding mechanisms that maintain the selected drivetrain mode without continuous electromagnetic force. Once the cam assembly is positioned in the desired mode, mechanical latching or spring forces maintain the position, allowing the electromagnetic coil to be de-energized. This self-service characteristic eliminates the need for continuous power input while maintaining operational reliability.
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 electromagnetic pulse disconnect assembly provides reliable and efficient power mode switching, consuming less power than continuous current systems, with a magnetic position sensor ensuring accurate monitoring of shifting motions and maintaining component longevity.
Implementation Method 1
an electromagnetic coil generating an axial force through an armature cam assembly
Data Source
AI summary
Methods and systems are provided for operating an electromagnetic pulse disconnect assembly for selectively engaging two rotating components of a vehicle drivetrain. A disconnect assembly is needed that is not powered by vacuum diverted from an engine of the vehicle, as modern engines are being developed to reduce vacuum production and remove vacuum lines for powering peripheral devices such as disconnects. An electromagnetic pulse disconnect assembly is provided that operates via pulses of electrical current and includes an electromagnetic coil for translating a clutch ring assembly and a latching ring assembly to selectively couple two rotating components.