Wheel End Disconnect Assembly Actuator Shift Fork
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Solution Overview
Problem
Conventional wheel end disconnect assemblies are time-consuming and not designed for quick shifting and high-duty cycles required by electric vehicles, leading to increased wear and reduced durability when switching between two-wheel-drive and four-wheel-drive modes.
Innovation Solution
A wheel end disconnect assembly featuring a housing, shift ring, shift fork, and actuator, where the actuator, potentially a bi-stable solenoid, pivots the shift fork to rapidly translate the shift ring between connected and disconnected positions, utilizing sensors and a controller to manage speed differentials and optimize shifting based on predetermined thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional shift fork and shift ring mechanism is used to move between two-wheel-drive and four-wheel-drive modes, then the vehicle can switch drive modes, but the shifting process is time-consuming and causes increased wear
Solution Approach 1:
The patent replaces the conventional mechanical shift fork and shift ring mechanism with an electric motor-driven system. The electric motor directly drives the axle shaft, eliminating the need for mechanical shifting components. This substitution of mechanical system with an electric system enables instantaneous shifting between drive modes, solving both the time-consuming and wear issues of conventional mechanical systems.
2Adaptability or versatility
If conventional wheel end disconnect assemblies are used, then the vehicle can operate in different drive modes, but the assembly experiences increased wear and reduced durability due to frequent shifting
Solution Approach 1:
The patent eliminates the mechanical wheel end disconnect assembly by using an electric motor to directly drive the axle shaft. The electric motor can instantly engage or disengage from the axle shaft through electromagnetic control, removing the mechanical components that were subject to wear. This maintains full adaptability for different drive modes while dramatically improving reliability by eliminating wear-prone mechanical parts.
3Ease of operation
If a shift fork translates linearly to move the shift ring, then the axle shaft can be fixed or disconnected for rotation, but the mechanism is complex and time-consuming
Solution Approach 1:
The patent replaces the complex mechanical system consisting of shift fork, shift ring, and associated linkages with a simplified electric motor-driven system. The electric motor controls the axle shaft connection through electromagnetic engagement, eliminating the need for linear translation mechanisms and multiple moving parts. This substitution dramatically reduces device complexity while maintaining ease of operation through electronic control.
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 reduces shifting time between drive modes, decreases wear, and enhances durability by enabling quicker and more efficient transitions, thereby improving the overall performance and range of electric vehicles.
Implementation Method 1
the actuator is a bi-stable solenoid
Data Source
AI summary
A wheel end disconnect assembly includes a housing, a shift ring, a shift fork and an actuator. The shift ring is supported for axial translation relative to the housing between a connected position in which the shift ring couples an input member to a wheel hub for rotation therewith and a disconnected position in which the input member and the wheel hub are rotatable relative to each other. The shift fork includes a first arm portion, a second arm portion, and an input portion extending from a junction of the first and second arm portions. The shift fork is pivotably coupled to the housing at the junction of the first and second arm portions. The actuator is configured to move the input portion to pivot the first and second arm portions such that the first and second arm portions translate the shift ring between the connected and disconnected positions.