Shift Isolation Lever for Power-Actuated Coupling
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Solution Overview
Problem
Current power-operated shift systems in four-wheel drive and all-wheel drive vehicles face challenges in addressing blocked shift conditions, which hinder the smooth transition of the clutch sleeve between engaged and disengaged positions, leading to increased power output requirements and reduced service life.
Innovation Solution
A clutch assembly with a shift isolation mechanism that biases the clutch sleeve towards an engaged position when blocked, and a power-operated clutch actuator with a spring-loaded arrangement to forcibly move the clutch sleeve into the engaged position once the blocked condition is resolved, ensuring conjoint rotation of rotary members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a spring-loaded mechanism is employed between the power-operated clutch actuator and the clutch sleeve, then the power output requirements are limited and service life is improved, but the complexity of the shift system increases
Solution Approach 1:
A spring-loaded shift isolation mechanism is introduced as an intermediary component between the clutch actuator and the clutch sleeve. This mechanism includes a shift isolation lever and spring assembly that mediates the force transmission, allowing the actuator to operate with reduced power output while still achieving reliable clutch engagement by isolating the sleeve from direct actuator forces during blocked shift conditions
2Reliability
If the clutch sleeve is forced to move into the engaged position during blocked tooth conditions, then the reliability of the shift system is enhanced, but the force required increases
Solution Approach 1:
A spring assembly is pre-configured in the shift isolation mechanism to provide cushioning force during blocked tooth conditions. The spring is positioned to engage and apply force to the shift isolation lever when the clutch teeth are blocked, enabling the system to overcome the blockage and complete the shift to the engaged position with enhanced reliability without requiring excessive force from the actuator
3Duration of action of moving object
If the shift isolation mechanism biases the clutch sleeve towards the engaged position, then the service life of the actuator is improved, but the device complexity increases
Solution Approach 1:
The shift isolation mechanism is designed to automatically bias the clutch sleeve toward the engaged position through the spring assembly without requiring additional control systems or actuators. The mechanism self-regulates by using the spring's stored energy to maintain optimal biasing force, thereby extending actuator service life through reduced operational stress while avoiding increased system complexity through autonomous operation
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
Enhances the reliability and efficiency of power-operated shift systems by allowing the clutch sleeve to move into the engaged position despite blocked tooth conditions, reducing power output requirements and improving service life.
Implementation Method 1
A solenoid actuator and a pivotable shift isolation mechanism coupling the solenoid actuator to the clutch sleeve
Implementation Method 2
a power-operated clutch actuator having an output member moveable between an extended position and a retracted position corresponding movement of the clutch sleeve
Data Source
AI summary
A clutch assembly incorporated into a power transfer assembly (72) of a motor vehicle is presented. The clutch assembly includes a power-operated clutch actuator (306) for moving a clutch sleeve (354) axially between released and engaged positions between two rotatory members. In the released position, relative rotation between two rotary members is prevented. Whereas in the engaged position, relative rotation is permitted. The power-operated clutch actuator (306) further includes an electromagnetic solenoid with an output member having an extended condition and a retracted condition urging the clutch sleeve (354) between positions. A shift isolation linkage mechanism (304) interconnects the output member of the solenoid to the clutch sleeve (354) and permits movement of the output member to its retracted position while a blocked tooth condition inhibits movement of the clutch sleeve (354) to its engaged position. Once the blocked tooth condition is removed, the isolation linkage mechanism (304) forces the clutch sleeve (354) to its engaged position.