Design, analysis and validation of a centralized shifting mechanism with an electrical actuator

Abstract

A sports utility vehicle (SUV) can be driven on different kinds of rugged surfaces and terrains. The shifting between different drive modes can improve fuel economy and handling based on driving conditions. This study aims to put forth a mechanism that will simplify the 2WD to 4WD switching and minimize the number of components. When a vehicle makes a turn while operating in 4WD mode, several stresses are induced, leading to driveline windup. The proposed mechanism will help in releasing the stress accumulation in driveline windup. A market survey was done to compare the efficiencies and reliability of different mechanisms available. Eventually, it was decided to use an electrical actuating system to engage and disengage the mechanism. A motion study was performed in SOLIDWORKS followed by Rapid Prototyping to verify its working to validate the design. This research also focuses on weight reduction and making the system compatible with different drivetrain layouts. FEA was performed in ANSYS to simulate the strength, reliability and compare different materials based on maximum deformation, equivalent von mises stress and factor of safety. This work aims to lay a foundation for future developments in the shifting mechanism used in an automobile.