Output Gear Integrated Disconnect for Low-Mass Torque Vectoring
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Solution Overview
Problem
Existing drive units with modular disconnect assemblies suffer from increased mass, assembly complexity, and power loss due to additional interfaces and contact points, which hinder efficient torque vectoring and weight distribution in vehicles.
Innovation Solution
The integration of disconnect components, such as a clutch assembly, directly into an output gear within a drive unit, reducing the number of components and interfaces, and utilizing a torque transfer adapter and clutch body actuatable by an external actuator to engage and disengage the clutch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modular disconnect assembly is used in a drive unit, then the disconnect function is achieved, but the mass and assembly complexity increase due to additional components and interfaces
Solution Approach 1:
The clutch assembly is integrated directly into the output gear, merging two previously separate components (clutch and gear) into a single unified structure. This eliminates the need for separate disconnect assemblies while maintaining the torque vectoring functionality, thereby reducing assembly complexity and component count
2Adaptability or versatility
If a modular disconnect assembly is used in a drive unit, then the disconnect function is achieved, but the overall mass increases due to additional components
Solution Approach 1:
By integrating the clutch assembly into the output gear, the patent eliminates redundant components and interfaces that would otherwise add mass. The unified structure reduces the overall weight of the drive unit while preserving the disconnect functionality needed for torque vectoring
3Adaptability or versatility
If multiple interfaces and contact points are added for disconnect assembly, then the disconnect function is achieved, but power loss increases due to additional contact points
Solution Approach 1:
The integration of the clutch assembly into the output gear reduces the number of interfaces and contact points in the torque transmission path. Fewer contact points mean reduced friction and power loss, while the disconnect function remains intact for effective torque vectoring control
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, enables efficient torque vectoring without compromising weight distribution, and allows for longer half shafts, enhancing durability and suspension articulation.
Implementation Method 1
a solenoid is coupled to the clutch body and the solenoid is configured to translate the clutch body to at least one of an engaged position and a disengaged position relative to the torque transfer adapter
Implementation Method 2
A first bearing is arranged laterally displaced from the actuator within a groove in the housing and configured to stabilize rotational motion of the output gear
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.