Support Ring Disconnector for Quiet 2WD/4WD Switching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disconnector apparatuses for switching between four-wheel drive and two-wheel drive result in increased vehicle length, weight, and noise due to complex operational structures and high differential issues when transitioning to two-wheel drive.
Innovation Solution
A disconnector apparatus featuring a support ring with a pinion gear that engages with a side gear, a clutch ring with a dog gear part, and a modularized actuator device, which includes a sleeve to move the clutch ring for engagement or disengagement, reducing the number of components and simplifying the assembly process while minimizing current consumption and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a ball screw shaft, fork, and disconnector sleeve are operated in conjunction with one another, then the disconnector apparatus can switch between four-wheel drive and two-wheel drive, but the overall length and space of the vehicle excessively increase
Solution Approach 1:
The patent merges the ball screw shaft and disconnector sleeve into a single integrated component. The disconnector sleeve is formed with an integrated ball screw shaft portion, eliminating the need for separate ball screw shaft, fork, and disconnector sleeve components. This integration significantly reduces the overall length and space required for the drive mode switching mechanism while maintaining the full functionality of switching between four-wheel drive and two-wheel drive modes.
2Adaptability or versatility
If a ball screw shaft, fork, and disconnector sleeve are operated in conjunction with one another, then the disconnector apparatus can switch between four-wheel drive and two-wheel drive, but the weight and mountability of the vehicle are adversely affected
Solution Approach 1:
The patent combines multiple components into a single integrated disconnector sleeve structure, reducing the total number of parts and associated fasteners, bearings, and mounting hardware. This integration directly reduces the overall weight of the disconnector apparatus while preserving the complete drive mode switching functionality between four-wheel drive and two-wheel drive operations.
3Adaptability or versatility
If the disconnector shaft and disconnector hub are disconnected for two-wheel drive, then the auxiliary driving wheel can be stopped, but the final gear is stopped and a high differential occurs causing noise and vibration
Solution Approach 1:
The patent introduces a support ring as an intermediary component that remains rotationally connected to the final gear even when the disconnector sleeve disconnects the drive shafts for two-wheel drive operation. This support ring acts as a mediator that allows the final gear to continue rotating at a reduced speed, preventing the high differential condition that causes noise and vibration while still enabling the auxiliary driving wheels to coast freely in two-wheel drive mode.
4Adaptability or versatility
If a complex operational structure with multiple components is used, then the disconnector apparatus can achieve drive mode switching, but the assembly and repair capabilities are reduced
Solution Approach 1:
The patent integrates the ball screw shaft and disconnector sleeve into a single monolithic component, dramatically reducing the number of parts that need to be assembled and disassembled. This integration simplifies the assembly process, reduces the number of fasteners and sealing interfaces, and makes repair and maintenance much easier while preserving the complete drive mode switching functionality. The modular design allows the entire disconnector assembly to be easily removed and replaced as a single unit if needed.
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
The solution reduces vehicle length and weight, minimizes noise by allowing the support ring to rotate during two-wheel drive, and enhances assembly and repair capabilities, improving packaging mountability and versatility.
Implementation Method 1
When a ball screw shaft 2b is rotated by an operation of a motor 2a of an actuator device 2, a ball screw nut 2c coupled to the ball screw shaft 2b moves along a guide rail 2d
Data Source
AI summary
Proposed is a disconnector apparatus including a support ring mounted in a casing and including a pinion gear mounted in the support ring and configured to engage with a first side gear, the support ring including a first dog gear part provided on one surface directed toward the first side gear, a clutch ring including a second dog gear part provided on one surface facing the support ring, the second dog gear part being configured to engage with the first dog gear part, and a sleeve connected to an actuator device and configured to move in an engagement direction or disengagement direction, the sleeve being connected to the clutch ring and configured to push the clutch ring in a direction toward the support ring or pull the clutch ring in a direction opposite to the support ring.