Side Gear Disconnect Assembly With Compact Axial Clutch Layout
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Solution Overview
Problem
Existing secondary electric powertrains in electric vehicles lack efficient side gear disconnectable differential assemblies that facilitate seamless transition between two-wheel drive and four-wheel drive modes, necessitating improved structural and functional interaction of power-operated disconnect devices.
Innovation Solution
A side gear disconnectable differential assembly with a power-operated mechanism, including a clutch unit, electromagnetic actuator, and biasing arrangement, allowing the output hub to shift between engaged and disengaged states, ensuring efficient torque transfer and reduced axial length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a power-operated disconnect mechanism is added to enable transition between two-wheel and four-wheel drive modes, then the adaptability and functionality of the electric powertrain is improved, but the device complexity and structural interaction requirements increase
Solution Approach 1:
The patent combines the disconnect mechanism components (clutch unit, electromagnetic actuator, biasing arrangement) into an integrated assembly that selectively couples the output hub to the side gear. This merging of components into a coordinated system enables the transition between two-wheel and four-wheel drive modes while managing the complexity through unified design rather than separate independent mechanisms.
2Ease of operation
If the output hub is designed to be axially shiftable to enable engagement and disengagement, then the ease of operation for mode transition is improved, but the manufacturing precision requirements for proper alignment and timing increase
Solution Approach 1:
The patent introduces a clutch unit as an intermediary mechanism between the output hub and side gear. This clutch unit facilitates the engagement and disengagement operation through axial shifting while incorporating features (such as splines and engagement surfaces) that guide and constrain the movement, thereby reducing the manufacturing precision requirements compared to a direct connection system.
3Reliability
If the disconnect mechanism is configured with multiple components (clutch unit, actuator, biasing arrangement), then the reliability of selective coupling and uncoupling is improved, but the assembly's axial length increases
Solution Approach 1:
The patent employs a nested arrangement where the electromagnetic actuator is positioned within or adjacent to the clutch unit, and the biasing arrangement is integrated into the same axial space. This nesting of components allows multiple functional elements to occupy overlapping or adjacent spatial zones, thereby reducing the overall axial length of the assembly while maintaining the reliability of the selective coupling and uncoupling 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
Enables smooth transition between two-wheel and four-wheel drive modes by effectively coupling and uncoupling the output hub with the side gear, optimizing power transfer and reducing the assembly's axial length.
Implementation Method 1
an electromagnetic actuator unit operable for shifting the disconnect mechanism between a first or 'engaged' state to establish the connected mode and a second or 'released' state to establish the disconnected mode
Data Source
AI summary
A disconnectable differential assembly has a reduced axial length and a side gear disconnectable from an axle shaft via a clutch unit. Various components of the disconnect mechanism are axially aligned and concentric to reduce the axial length. An output hub splined on the axle shaft and is actuatable, via an axially shiftable armature, into toothed engagement with the side gear via respective axially extending teeth. The output hub and armature include radially extending flanges that are axially adjacent and radially aligned with the teeth so that force is transmitted to the teeth at the same diameter. A thrust bearing is disposed between the flanges so that the output hub rotates relative to the armature. The side gear is supported for rotation on the axle shaft, and a bearing is disposed radially therebetween to improve radial alignment of the second side gear with the output hub.