Integrated Shaft Blocking Mechanism With Low Actuation Force

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Solution Overview

Problem

Existing locking mechanisms for vehicles are not compact, cost-effective, and energy-efficient, particularly in the context of electric motor drive units, and they require high actuating forces to engage the shaft.

Innovation Solution

A locking mechanism with a positive locking element that is electrically actuated and pre-tensioned via an elastic force transmission means, integrated into the locking actuator, allowing engagement with a shaft-side complement using a play and minimal actuator force, and is integrated into the electric motor drive unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional blocking mechanism with shaft engagement and release is used, then the drivetrain can be blocked and unblocked, but the mechanism requires multiple components (shaft, blocking mechanism, release mechanism) increasing device complexity

Engineering Contradiction:

Improveblocking functionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the blocking mechanism and release mechanism into a single integrated unit. The blocking member is directly coupled to the actuator, eliminating the need for separate shaft, blocking mechanism, and release mechanism components. This merging reduces device complexity while maintaining the blocking and unblocking functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The actuator serves multiple functions: it directly blocks the drivetrain by engaging the blocking member with the drive shaft, and it directly releases the blocking by retracting. This multi-functionality eliminates the need for separate dedicated blocking and releasing components, reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a blocking mechanism with multiple components is used, then the drivetrain can be blocked, but the volume occupied by the blocking mechanism increases

Engineering Contradiction:

Improveblocking functionVSAvoidvolume of blocking mechanism

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

By merging the blocking and release functions into a single integrated actuator unit, the overall volume required for the blocking mechanism is reduced. The combined structure occupies less space than separate components would require.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The blocking member is designed to nest within or alongside the actuator structure when not in use. The actuator housing integrates the blocking member, allowing compact arrangement that minimizes the volume occupied by the blocking mechanism.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If a conventional blocking mechanism is used, then the drivetrain can be blocked and unblocked, but the mass of the blocking mechanism increases

Engineering Contradiction:

Improveblocking functionVSAvoidmass of blocking mechanism

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the blocking member and actuator into a single integrated unit, eliminating the mass of separate shaft, blocking mechanism, and release mechanism components. This integration reduces the total mass while maintaining blocking functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The actuator performs both blocking and releasing functions, eliminating the need for separate dedicated components. This multi-functionality reduces the total number of parts and their combined mass.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If a blocking mechanism with separate shaft and blocking mechanism is used, then the drivetrain can be blocked, but the manufacturing complexity increases

Engineering Contradiction:

Improveblocking functionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The blocking mechanism and actuator are designed as an integrated unit that can be manufactured as a single assembly or pre-assembled module. This reduces manufacturing complexity compared to producing and assembling separate shaft, blocking mechanism, and release mechanism components.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4441399B1Blocking mechanism, electric motor drive unit, vehicle, and method for blocking a shaft of a drivetrain

Publication Date: 2026.05.06 SCHAEFFLER TECHNOLOGIES AG & CO KG

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AI summary

The invention relates to a blocking mechanism (2), in particular of a vehicle, between a blocking actuator (4) and a blockable shaft (6) of a drivetrain, in which a form-fitting element (8), which can be actuated in an axial stroke movement (X-X) and along the shaft (6), in a state bearing at the end against a shaft-side complement (10) to which the form-fitting element (8) can be form-fittingly joined in some sections, can be preloaded lockably in a defined manner against the shaft-side complement (10) along the shaft (6) by means of at least one elastic force transmission means (12). The elastic force transmission means (12) is integrated into the form-fitting element (8). In a blocked state of the shaft (6), in which the form-fitting element (8) and the shaft-side complement (10) interlock in a form-fitting region (FB) of the blocking mechanism (2), the form-fitting element (8) is supported against a housing section (EM-G) of an electric motor drive unit (EM-AE) to which the blocking actuator (4) is attached. The blocking mechanism (2) has, in the form-fitting region (FB) and in the circumferential direction of the shaft (6), a movement clearance (BS) between the form-fitting element (8) and the shaft-side complement.