Twin Side Shaft Torque Coupling for Driveline Energy Loss
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Solution Overview
Problem
All-wheel drive vehicles experience energy loss and reduced fuel economy due to the continuous operation of secondary drivelines, which are not providing additional traction, leading to friction and spin losses.
Innovation Solution
A rear wheel drive unit with a twin side shaft torque coupling system that includes an intermediate shaft, clutch drums, and actuator assemblies, allowing for selective engagement and disengagement to optimize driveline efficiency and traction by disconnecting the secondary driveline during idle conditions and engaging it for additional traction when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the secondary driveline operates continuously, then additional traction is available, but energy loss increases and fuel economy deteriorates
Solution Approach 1:
The patent implements a dynamic driveline system where the secondary driveline can be selectively engaged or disengaged based on operating conditions. The torque coupling device allows the system to transition between connected and disconnected states, enabling the secondary driveline to rotate independently when not needed, thereby eliminating friction and spin losses while maintaining traction when required.
Solution Approach 2:
The driveline is segmented into primary and secondary components that can operate independently. The torque coupling device acts as a separator that allows the secondary driveline to be disconnected from the primary driveline, enabling independent rotation of the secondary component without dragging the entire system, thus reducing energy loss.
2Loss of energy
If the secondary driveline is disconnected to improve fuel economy, then energy loss is reduced, but additional traction is lost when needed
Solution Approach 1:
The system incorporates sensors and control logic that continuously monitor driveline operating conditions, wheel slip, and traction requirements. When the system detects conditions requiring additional traction, it automatically engages the torque coupling to connect the secondary driveline. When traction conditions are sufficient, the system disengages the coupling to eliminate energy losses, creating a responsive feedback-controlled system.
3Adaptability or versatility
If a torque coupling is used to limit torque flow, then differences in speed between drivelines are accommodated, but device complexity increases
Solution Approach 1:
The torque coupling device serves as an intermediary component between the primary and secondary drivelines. It includes a clutch drum, clutch plates, and actuator assembly that mediates the connection and disconnection of torque flow. This intermediary mechanism allows the system to accommodate speed differences by selectively engaging or disengaging the coupling, providing adaptability without requiring complex continuous variable mechanisms.
Data Source
AI summary
A drive unit with twin side shaft torque coupling has an intermediate shaft with a first end portion and a second end portion and a central portion with a ring gear. A first clutch drum is directly mounted on the first end portion of the intermediate shaft. The first clutch drum has a first plurality of clutch plates. A first clutch can is located radially inboard of the first clutch drum. The first clutch can supports selective axial movement of a second plurality of clutch plates. The first and second plates are interleaved with one another to form a clutch pack. The first clutch can is connected to one end portion of a first output shaft located radially inboard from said first clutch can. A first clutch actuator assembly selectively actuates the first clutch. The drive unit also comprises a second clutch drum, clutch can and clutch actuator assembly.