Nearly all AWD vehicles on the market today feature some sort of disconnect mechanism in their powertrain due to efficiency requirements.

The invention presented herein aims to reduce the cost of such a system, while also reducing the remaining power dissipation in comparison to current systems. A diverse group of students, researchers and experienced industry specialists at the Institute of Machine Components and Methods of Development at the Graz University of Technology teamed up to bring an unconventional idea to life.

A prototype design of the disconnect differential was derived from an existing series production bevel gear differential, focusing on simplicity and ease of manufacturing. The switching operation in various service conditions was examined using analytic models, as well as a physical technology demonstrator, that was built using rapid prototyping methods.

Finally, the developed system was compared to state-of-the-art technology in terms of weight, size and loss reduction amongst other criteria. The improvements were illustrated and possible combinations and applications for this technology were pointed out.