Hydraulic Disc Coupling Mechanical Locking Mechanism
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Solution Overview
Problem
In AWD systems using a hydraulic power source, there is a need for an added locking function, especially when the vehicle is parked on a hill, as existing solutions cannot guarantee a complete leakage-free torque distribution without mechanical locking, and hydraulic power source unloading is required during off-road driving situations.
Innovation Solution
A mechanically lockable hydraulic coupling with an integrated locking arrangement that converts rotational movement to axial movement to secure the coupling piston against the disc package, allowing engagement without hydraulic pressure, using a gear rack piston actuated by hydraulic pressure and a self-locking thread mechanism for secure locking and easy actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic pressure is used to maintain coupling engagement, then torque distribution is achieved, but leakage cannot be completely prevented over time and hydraulic power source must remain pressurized
Solution Approach 1:
The patent replaces the hydraulic pressure-based mechanical engagement system with a mechanically locked system. The locking member engages with the coupling piston to provide a purely mechanical locking mechanism that maintains engagement without requiring continuous hydraulic pressure, thereby eliminating hydraulic leakage issues and energy consumption for pressure maintenance.
Solution Approach 2:
The locking arrangement is designed to automatically lock the coupling piston in the engaged position once hydraulic pressure has initially compressed the disc package. The system uses its own hydraulic pressure to actuate the locking member, which then maintains engagement independently without requiring continued external power or pressure maintenance.
2Reliability
If mechanical locking is added to the hydraulic coupling, then leakage-free operation is achieved, but device complexity increases
Solution Approach 1:
The locking arrangement is integrated into the existing hydraulic coupling structure. The locking member is positioned within the coupling housing and works in conjunction with the existing coupling piston and disc package, merging the locking function with the existing torque distribution mechanism rather than adding a completely separate system.
Solution Approach 2:
The coupling piston serves dual functions: it compresses the disc package for torque distribution and simultaneously acts as the element to be locked by the locking member. This multi-functionality reduces the need for additional separate components dedicated solely to locking.
3Use of energy by moving object
If hydraulic pressure is removed from the coupling, then power source can be turned off, but coupling engagement is lost
Solution Approach 1:
Hydraulic pressure is applied in advance to compress the disc package and establish engagement, and simultaneously to actuate the locking member into the locked position. Once locked, the system can be powered down while maintaining engagement through the mechanical lock, separating the engagement establishment phase from the maintenance phase.
Solution Approach 2:
The continuous hydraulic pressure system is replaced with a mechanical locking system for maintaining engagement. The locking member provides a passive mechanical constraint that holds the coupling piston in position without requiring active hydraulic pressure, enabling complete power source shutdown while maintaining engagement.
4Volume of moving object
If locking arrangement is integrated into the coupling, then compact design is achieved, but manufacturing complexity increases
Solution Approach 1:
The locking member is positioned within the coupling housing and interacts with the coupling piston in a nested arrangement. The locking arrangement components are contained within the existing coupling structure, utilizing the available internal space rather than adding external protrusions or separate assemblies.
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 secure engagement and locking of the coupling without hydraulic pressure, maintaining vehicle stability on inclines and during off-road conditions, while minimizing the need for external power sources and ensuring no slip in the disc package, allowing for complete powerlessness without losing engagement.
Implementation Method 1
a gear rack piston actuated by pressure generated by the hydraulic pump of the coupling
Implementation Method 2
said locking arrangement is configured to convert a rotational movement to an axial movement upon actuation, wherein said axial movement is used for pressing the coupling piston towards the disc package
Implementation Method 3
a disc package and a coupling piston acting thereon, said coupling piston being actuated by an hydraulic pressure generated by the hydraulic pump in order to distribute the torque from an input to an output of the coupling
Data Source
AI summary
A hydraulic disc coupling (1) for a system distributing torque between the left and right wheels and/or the front and rear axles of a vehicle is provided. A coupling piston (6) is configured to be mechanically locked by an integrated locking arrangement (23), when the coupling piston (6) is actuated to act on the disc package (8), such that the coupling remains engaged whereby the input (2) is connected to the output (7) of the coupling (1) without hydraulic pressure acting on the coupling piston (6). Unlocking of the integrated locking arrangement (23) is provided by again actuating the coupling piston (6).