Wheel End Disconnect Actuator for Precise Clutch Shifting
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Solution Overview
Problem
Existing wheel end disconnect systems face challenges in efficiently and reliably initiating the shifting action of a clutch to engage or disengage drive and driven shafts, particularly in converting between two-wheel and four-wheel drive modes.
Innovation Solution
The proposed actuator system includes a solenoid-mounted housing with a rocker and shift fork mechanism, where activation of the solenoid causes the rocker to pivot, translating the shift fork along a translation pin to engage or disengage the clutch ring, and a control unit monitors the position of the magnet on the shift fork to ensure proper shifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a traditional actuator mechanism is used to initiate clutch shifting action, then the system can achieve engagement/disengagement of drive and driven shafts, but the mechanism becomes complex and space-consuming
Solution Approach 1:
The actuator mechanism is segmented into distinct functional components: a solenoid for initiating motion, a rocker arm for amplifying and directing force, and a shift fork for executing the clutch engagement/disengagement. This segmentation allows each component to be optimized independently while reducing overall complexity and improving reliability through modular design.
Solution Approach 2:
The rocker arm serves as an intermediary mechanism between the solenoid and the shift fork. It translates the linear motion of the solenoid plunger into rotational motion, which then drives the shift fork to move the clutch. This intermediary mechanism simplifies the overall system by providing a mechanical advantage and decoupling the direct connection between actuator and clutch.
2Manufacturing precision
If a manual or simple actuation method is used for clutch shifting, then the device complexity is reduced, but the precision and control over engagement/disengagement deteriorates
Solution Approach 1:
A sensor is integrated into the actuator system to detect the position of the clutch during engagement and disengagement. This feedback mechanism provides real-time information to the control system, enabling precise control of the shifting action and ensuring accurate clutch engagement without requiring overly complex mechanical positioning mechanisms.
Solution Approach 2:
The traditional purely mechanical actuation system is replaced with an electro-mechanical system. The solenoid provides electrically controlled actuation, replacing manual or simple mechanical linkages. This substitution enables precise control through electrical signals while maintaining mechanical reliability through the rocker arm and shift fork mechanism.
3Adaptability or versatility
If multiple disconnect points are implemented in the drive line, then the conversion between two-wheel and four-wheel drive is more flexible, but the overall system complexity and number of moving parts increases
Solution Approach 1:
The actuator mechanism designed for the front wheel disconnect is made universal and can be applied to multiple disconnect points in the drive line, including the differential disconnect and rear wheel disconnect. This multi-functional design reduces overall system complexity by using the same proven mechanism in different locations rather than designing unique actuation systems for each disconnect point.
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
This solution enables precise and reliable control over the engagement and disengagement of the clutch, ensuring smooth transitions between two-wheel and four-wheel drive modes, while also providing a durable and space-efficient design.
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
a magnet is mounted to the shift fork and a sensor is mounted to the housing for sensing a position of the magnet on the shift fork relative to the housing
Data Source
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.