Wheel End Disconnect Actuator with Rocker-Shift Fork Control
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Solution Overview
Problem
Existing systems for converting between two-wheel and four-wheel drive in vehicles lack efficient and reliable actuators for engaging and disengaging drive and driven shafts, particularly in systems with a center disconnect or differential disconnect, which can lead to involuntary shifts due to unbalanced G-loading and potential binding issues.
Innovation Solution
An actuator system with a solenoid, rocker, and shift fork mechanism that includes a pivotally mounted rocker and a translation pin, utilizing a bi-stable solenoid with magnetic latching for precise control, and a position sensor for feedback, ensuring balanced G-loading and minimizing stiction, with customizable rocker profiles and adjustable solenoid orientations for optimal fit and force transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional actuator mechanism is used for wheel end disconnect, then the structure is simple, but involuntary shifts occur due to unbalanced G-loading and binding issues
Solution Approach 1:
The patent modifies the actuator mechanism by changing parameters such as adding a rocker arm with specific geometry, incorporating a translation pin with controlled movement, and using a bi-stable solenoid with magnetic latching. These parameter changes transform the simple but unreliable actuator into a more complex but reliable system that prevents involuntary shifts while maintaining controlled operation.
2Ease of operation
If a bi-stable solenoid with magnetic latching is used, then precise control and balanced G-loading are achieved, but the device complexity increases
Solution Approach 1:
The bi-stable solenoid with magnetic latching serves itself by maintaining its position without continuous power input. The magnetic latching mechanism automatically holds the solenoid in either engaged or disengaged state, providing self-servicing functionality that reduces the need for continuous control input while achieving precise control and balanced G-loading.
3Measurement precision
If a position sensor with feedback control is implemented, then shift accuracy is improved, but the device complexity and material usage increase
Solution Approach 1:
The position sensor provides real-time feedback on the actuator's position to the control system. This feedback loop allows the controller to monitor and adjust the actuator position, ensuring accurate engagement and disengagement of the clutch ring. The feedback mechanism improves measurement precision while the controlled response prevents excessive complexity by using the information efficiently.
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 actuator system provides reliable and efficient engagement and disengagement of drive shafts, minimizing involuntary shifts and reducing material usage, while allowing for flexible packaging and compatibility with various vehicle designs.
Implementation Method 1
a solenoid mounted to the housing, the solenoid is actuatable to move a plunger in a fore and aft direction
Implementation Method 2
utilizing a bi-stable solenoid with magnetic latching for precise control
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
An actuator for a wheel end disconnect system includes a housing and a solenoid mounted to the housing, the solenoid is actuatable to move a plunger in a fore and aft direction. A rocker is pivotally mounted to the housing and is connected to the plunger. A shift fork slidably mounted on a translation pin extending from the housing, the shift fork including a channel for receiving an end of the rocker, wherein activation of the solenoid causes pivotal movement of the rocker to cause the shift fork to translate along the translation pin.