Wheel-End Rotational Disconnect Assembly Torque Management
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Solution Overview
Problem
Conventional automotive powertrain systems face challenges in efficiently disconnecting drivelines to minimize parasitic losses and optimize torque distribution, leading to increased complexity and manufacturing costs.
Innovation Solution
A wheel-end disconnect assembly comprising a knuckle bracket, a clutch assembly, and an electromagnetic actuator that allows for selective torque interruption between the output shaft and wheel hub, enabling efficient rotational torque management without continuous electrical supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional rotational disconnect systems are used to selectively interrupt rotation between powertrain components, then torque distribution can be optimized and parasitic losses minimized, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the rotational disconnect mechanism directly with the wheel hub assembly, merging previously separate components (disconnect mechanism, wheel hub, and mounting structure) into a single integrated unit. This integration eliminates the need for separate disconnect assemblies and reduces the number of parts, thereby optimizing torque distribution while minimizing the increase in device complexity.
Solution Approach 2:
The wheel hub assembly is designed to serve multiple functions: it supports the wheel, enables rotational disconnect, and provides mounting for brake components. By making the wheel hub multi-functional, the patent achieves torque optimization capabilities without adding dedicated separate components, thus reducing overall system complexity while minimizing parasitic losses.
2Productivity
If rotational disconnect mechanisms are added to selectively interrupt driveline rotation, then powertrain efficiency improves, but packaging size increases
Solution Approach 1:
The disconnect mechanism is merged with the wheel hub assembly, utilizing the existing wheel hub structure and space. By integrating the disconnect functionality into the wheel hub rather than adding a separate mechanism, the patent improves powertrain efficiency through selective torque interruption while minimizing the increase in packaging size.
Solution Approach 2:
The rotational disconnect mechanism is nested within the wheel hub assembly structure, with disconnect components positioned inside or around the wheel hub's existing geometry. This nesting approach allows the disconnect functionality to be accommodated within the existing packaging envelope, improving powertrain efficiency without significantly increasing overall vehicle packaging requirements.
3Ease of operation
If complex rotational disconnect systems with continuous electrical supply are used, then precise torque control is achieved, but manufacturing cost and system weight increase
Solution Approach 1:
The electromagnetic actuator is designed as a bi-stable device that uses periodic or intermittent electrical activation rather than continuous power supply. The actuator can be energized briefly to transition between stable states (engaged/disconnected positions), then maintains its position without continuous power. This approach achieves precise torque control through stable positioning while minimizing weight by eliminating continuous electrical supply requirements and associated heavy-duty wiring and power management systems.
Solution Approach 2:
The bi-stable electromagnetic actuator utilizes its own magnetic field and mechanical structure to maintain positioned states without external power. Once activated to a desired position, the actuator self-maintains that position through its inherent magnetic and mechanical stability, eliminating the need for continuous electrical supply and heavy power management systems, thus reducing overall system weight while maintaining precise torque 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 enhances powertrain system performance by reducing packaging size, manufacturing complexity, and costs while improving efficiency, weight, and drivability across various driving conditions.
Implementation Method 1
an electromagnetic actuator having a slider selectively movable between a first stable position and a second stable position
Data Source
AI summary
A wheel-end disconnect assembly for translating rotational torque between an output shaft and a wheel hub of a vehicle driveline. A knuckle bracket at least partially supports the wheel hub. A clutch is operatively attached to the knuckle bracket, is disposed in selective torque translating relationship between the output shaft and the wheel hub, and is movable between: an engaged configuration wherein torque is translated between the output shaft and the wheel hub, and a disengaged configuration wherein torque is interrupted. An electromagnetic actuator is provided and has a slider selectively movable between a first stable position and a second stable position. The actuator is disposed in force translating relationship with the clutch such that movement from one stable position to the other stable position causes corresponding movement of the clutch between the configurations so as to selectively translate rotational torque between the output shaft and the wheel hub.