Integrated Output Gear Disconnect to Cut Drive Unit Mass
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Solution Overview
Problem
Modular disconnect assemblies in drive units result in redundancy, increased mass, and power loss due to additional interfaces, which hinder uniform translation of input forces to output forces and compromise weight distribution and packaging in vehicles.
Innovation Solution
An integrated clutch assembly is incorporated into the output gear, reducing the number of components and mass, and enabling torque vectoring by actuating a clutch body through a solenoid to engage or disengage with a torque transfer adapter, while sensors communicate the clutch position to a network for efficient control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modular disconnect assemblies are used in drive units, then the disconnect function is achieved, but the mass and size of the drive unit increase due to redundancy and additional interfaces
Solution Approach 1:
The clutch assembly is integrated directly into the output gear, merging two previously separate components (clutch assembly and output gear) into a single unified component. This eliminates redundant interfaces and reduces the overall mass and size of the drive unit while maintaining the disconnect function.
Solution Approach 2:
The output gear is designed to serve multiple functions: it acts as both the gear for power transmission and as the housing for the clutch assembly. This multi-functionality eliminates the need for separate disconnect assembly components, reducing redundancy and mass.
2Reliability
If modular disconnect assemblies are used in drive units, then the disconnect function is achieved, but power loss occurs due to additional interfaces
Solution Approach 1:
By integrating the clutch assembly into the output gear, the number of interfaces is reduced. Fewer interfaces mean fewer potential sources of power loss, improving the efficiency of power transmission while maintaining the disconnect function.
3Reliability
If modular disconnect assemblies are used in drive units, then the disconnect function is achieved, but weight distribution and vehicle packaging are compromised
Solution Approach 1:
The integration of the clutch assembly into the output gear reduces the overall mass of the drive unit. This mass reduction improves vehicle weight distribution and facilitates better packaging within the vehicle constraints.
4Weight of moving object
If components are integrated inside the output gear cavity, then mass and size are reduced, but the complexity of actuating the clutch body increases
Solution Approach 1:
A solenoid actuator is used as an intermediary device to actuate the clutch body through the output gear. The solenoid converts electrical signals into mechanical motion, providing a compact and efficient means of actuating the clutch body integrated within the output gear cavity.
Solution Approach 2:
The mechanical actuation system is replaced with an electromagnetic solenoid actuator. This substitution reduces the complexity of mechanical linkages and provides more precise control over the clutch body position while maintaining integration within the output gear.
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
This solution reduces the overall mass and size of the drive unit, enhances durability, and allows for longer half shafts and increased suspension articulation, while enabling efficient torque vectoring without compromising weight distribution or vehicle packaging.
Implementation Method 1
a solenoid configured to translate the clutch body to at least one of an engaged position and a disengaged position relative to the torque transfer adapter
Data Source
AI summary
Systems and methods are presented herein for providing an integrated disconnect. The integrated disconnect may be used within a drive unit. The integrated disconnect comprises an output gear having a cavity. A torque transfer adapter is arranged within the cavity. A clutch body is also arranged within the cavity. The clutch is actuatable through the output gear by an actuator to engage and disengage the clutch with the torque transfer adaptor. The actuator is located external to the cavity.