Hybrid Vehicle Disconnector With Linear Sensor Feedback
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Solution Overview
Problem
Conventional hybrid vehicles experience reduced engine efficiency due to the use of clutches for interrupting and transmitting rotary power, and existing systems lack precise control over the shift fork's transfer distance for accurate power management.
Innovation Solution
A disconnector system for hybrid vehicles that incorporates a linear sensor to accurately measure and monitor the transfer distance of a shift fork, utilizing an actuator with a reversible motor and lead screw to control the shift fork's movement, ensuring precise control over rotary power interruption and transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clutch is used to interrupt or transmit rotary power in conventional hybrid vehicles, then the power transmission function is achieved, but engine efficiency is reduced
Solution Approach 1:
The patent removes the clutch component from the power transmission system and replaces it with a disconnector mechanism consisting of a shift fork, sleeve, and sensor system. This extraction of the clutch eliminates the energy losses associated with clutch engagement and disengagement while maintaining the essential power interruption and transmission functions.
Solution Approach 2:
The patent replaces the mechanical clutch system with a sensor-controlled disconnector mechanism. The linear sensor detects the position of the shift fork, and the controller manages power transmission based on this feedback, substituting mechanical friction-based engagement with a more efficient mechanical linkage system monitored by electronic sensors.
2Device complexity
If conventional power transmission control is used without precise measurement, then the system structure is simple, but the transfer distance of the shift fork cannot be accurately controlled
Solution Approach 1:
The patent incorporates a linear sensor that continuously detects the position of the shift fork and provides feedback to the controller. This feedback mechanism enables precise measurement of the transfer distance, allowing the controller to accurately control the engagement and disengagement states of the power transmission system.
Solution Approach 2:
The linear sensor acts as an intermediary between the mechanical shift fork and the electronic controller. It converts the mechanical position information into electrical signals that the controller can process, enabling precise measurement and control without directly complicating the mechanical structure of the shift mechanism itself.
3Measurement precision
If precise control of shift fork transfer distance is implemented using a linear sensor, then power transmission control accuracy is improved, but device complexity increases
Solution Approach 1:
The linear sensor is directly mounted on the housing and utilizes the existing movement space of the shift fork. The sensor self-adjusts to detect the position changes without requiring additional complex mounting mechanisms or calibration systems, thereby minimizing the increase in device complexity while achieving precise measurement.
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 and accurate control of rotary power transmission and interruption by precisely measuring the shift fork's transfer distance, enhancing engine efficiency and power management in hybrid vehicles.
Implementation Method 1
a linear sensor sensing a transfer distance of the shift fork
Implementation Method 2
a lead screw converting a rotary motion into a linear motion
Implementation Method 3
a first spring installed between the upper housing and the shift fork
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Disclosed is a disconnector for a hybrid vehicle that includes an upper housing (1) connected to a reducer (A), an input shaft (3) installed inside the upper housing (1) and transmitting rotary power of the reducer (A), bearings (9 and 10) installed between the upper housing (1) and the input shaft (3), a hub (4) disposed under the input shaft (3), a sleeve (5) having an inner circumferential surface spline-coupled to outer circumferential surfaces of the input shaft (3) and the hub (4) to then be shifted to transmit or interrupt the rotary power of the input shaft (3) to the hub (4), a shift fork (6) coupled to an outer circumferential surface of the sleeve (5) and shifting the sleeve (5), a first spring (12) installed between the upper housing (1) and the shift fork (6), a lower case (2) connected to a lower portion of the upper housing (1), a constant velocity joint (B) connected to the hub (4) through the inside of the lower case (2), a needle roller (11) installed between the lower case (2) and the constant velocity joint (B), an actuator (8) coupled to the inside of the lower case (2) and pushing out the shift fork (6), and a linear sensor (15) sensing a transfer distance of the shift fork (6).