Twin-Fork Actuator for 4WD Power Transmission
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Solution Overview
Problem
Modern vehicle drivelines with four-wheel drive capabilities require power transmitting components that can operate in both two-wheel high-speed and four-wheel low-speed modes, but existing configurations with clutches and transmissions are susceptible to improvements in terms of functionality and efficiency.
Innovation Solution
A power transmitting component featuring a twin-fork actuator system with a motor, transmission, lead screw, and cradle assembly, which includes a first and second fork, allowing for coordinated movement between the forks to manage mode and range positions, enabling efficient operation in various drive modes by utilizing an actuator housing, rails, and springs to ensure proper engagement and power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single actuator with one fork is used to control clutch engagement, then the device complexity is reduced, but the adaptability to control multiple clutch forks for different drive modes is insufficient
Solution Approach 1:
The patent combines two separate clutch fork actuators into a single integrated actuator unit. The first and second clutch forks are both actuated by a single motor (1002) through a shared transmission (1004) and lead screw (1008) mechanism, reducing the number of independent actuators while maintaining the capability to control both forks for different drive mode operations.
Solution Approach 2:
The single actuator housing (1000) is designed to perform multiple functions: it houses the transmission and lead screw mechanism, supports both the first and second clutch forks through shared rails (1010, 1012), and enables control of multiple clutch engagements. This multi-functional design reduces overall system complexity while maintaining adaptability across different drive modes.
2Ease of operation
If separate actuators are used for each clutch fork, then the control precision is improved, but the device complexity increases
Solution Approach 1:
The patent merges the control functions of two separate actuators into one integrated actuator system. The single motor (1002) drives the transmission (1004) which in turn actuates both the first and second clutch forks through the lead screw mechanism, reducing the number of actuators from two to one while maintaining coordinated control capability.
Solution Approach 2:
The lead screw (1008) acts as an intermediary mechanism that translates the rotational motion from the single motor into coordinated linear motion for both clutch forks. The cradle assembly (1014) with its yokes (2022, 2024) serves as a mediator that distributes the actuating force from the lead screw to both forks simultaneously, enabling precise control without requiring separate actuators.
3Adaptability or versatility
If a twin-fork actuator system is implemented, then the operational flexibility is improved, but the manufacturing complexity increases
Solution Approach 1:
The actuator system is segmented into distinct functional modules: the actuator housing (1000), transmission assembly (1004), lead screw mechanism (1008), cradle assembly (1014), and two independent fork assemblies. This segmentation allows each module to be manufactured and tested separately before final assembly, reducing the overall manufacturing complexity despite the sophisticated integrated design.
Solution Approach 2:
The actuator housing (1000) is designed as a universal platform that accommodates multiple functions: it houses the transmission and lead screw, supports both clutch forks through shared rails, and provides mounting points for springs and dampers. This multi-functional housing reduces the total number of separate components needed, simplifying the assembly process while maintaining operational flexibility for multiple drive modes.
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 twin-fork actuator system enhances the operational flexibility and efficiency of power transmitting components, allowing seamless transitions between two-wheel high-speed, four-wheel high-speed, neutral, and four-wheel low-speed modes, while ensuring proper power transmission and limiting power when not fully engaged, thus improving the overall drivetrain functionality.
Implementation Method 1
The lead screw is rotatable about a first axis, the lead screw being driven by the transmission
Implementation Method 2
The cradle assembly is driven by the lead screw axially along the first axis
Implementation Method 3
The first clutch fork is slidably mounted on the first rail. The second clutch fork is slidably mounted on the second rail
Data Source
AI summary
A power transmitting component having a actuator with a lead screw, which is driven by a motor and a transmission, a pusher assembly driven by the lead screw, and a clutch fork. Translation of the pusher coordinates movement of the clutch fork along its axis.