Electromagnetic Pulse Disconnect Assembly for Powertrain
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Solution Overview
Problem
Existing powertrain disconnect systems in vehicles rely on vacuum power, which is unreliable due to fluctuations in engine throttle settings and altitude, and may not be available in all vehicles, leading to inconsistent performance and increased system complexity.
Innovation Solution
An electromagnetic pulse disconnect assembly using a coil assembly with an armature cam and cam follower, along with a latching system, to selectively engage and disengage rotating components, powered by discrete electrical pulses, eliminating the need for vacuum power and reducing system complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If vacuum power is used to actuate the disconnect system, then the system can be simpler in structure, but the reliability deteriorates due to vacuum fluctuations from engine throttle settings and altitude changes
Solution Approach 1:
The patent replaces the vacuum-powered diaphragm actuator with an electromagnetic coil assembly that uses electromagnetic fields to actuate the armature cam. This substitution eliminates dependence on vacuum pressure fluctuations from engine operation, providing reliable actuation across all driving conditions while maintaining actuator simplicity.
Solution Approach 2:
The patent changes the actuation parameter from vacuum pressure to electrical current. The electromagnetic coil assembly responds to electrical signals rather than vacuum pressure, making the disconnect system immune to altitude and throttle-induced vacuum variations while preserving the simple single-component actuator design.
2Ease of operation
If electromagnetic coils are used in wet plate clutches or locking differentials, then motion control is improved, but the device complexity and packaging space increase significantly
Solution Approach 1:
The electromagnetic actuator is segmented into three compact functional components: the coil assembly, armature cam, and cam follower. This segmentation allows each component to be optimized for its specific function while maintaining a compact overall package that fits within existing drivetrain spaces.
Solution Approach 2:
The electromagnetic coil assembly serves multiple functions: it provides the actuating force, guides the armature cam motion, and interfaces with the clutch mechanism. This multi-functionality reduces the number of separate components needed compared to traditional wet plate clutch designs, simplifying the overall system.
3Volume of moving object
If vacuum-powered disconnect systems are used, then the system can be compact, but the reliability deteriorates due to vacuum unavailability in vehicles without vacuum-powered accessories
Solution Approach 1:
The patent replaces the vacuum-dependent diaphragm actuator with an electromagnetic coil assembly that uses electrical power, which is universally available in all modern vehicles. This substitution maintains compact system dimensions while ensuring reliable operation regardless of whether the vehicle has vacuum-powered accessories.
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 solution provides reliable and efficient engagement and disengagement of drivetrain components, reducing power consumption and system size, while maintaining flexibility and adaptability to different driving conditions.
Implementation Method 1
an electromagnetic coil assembly including an electromagnetic coil arranged within an annular housing of the coil assembly
Data Source
AI summary
Methods and systems are provided for an electromagnetic pulse disconnect assembly. In one example, an electromagnetic disconnect assembly includes an electromagnetic coil assembly including an electromagnetic coil, an armature cam including an annular ring and a plurality of bidirectional cam ramps extending in an axial direction from the annular ring, where the annular ring is adapted to have face-sharing contact with the electromagnetic coil assembly when the electromagnetic coil is energized and be spaced apart from the electromagnetic coil assembly when the electromagnetic coil is de-energized, and a cam follower a plurality of radially extending guides arranged around a circumference of the cam follower and spaced apart from one another via a plurality of elongate apertures, each of the plurality of elongate apertures adapted to receive one of the plurality of bidirectional ramps of the armature cam. The assembly may further include a latching system.