Stator for rotating device

Abstract

A stator of a lock differential includes an inner lip recessed into a central opening. The inner lip is engaged with the bearing race to secure the stator to a gear housing of a lock-in differential. The stator holds the electromagnetic coil. The stator is shaped to avoid electromagnetic flux pinch points that may limit the magnitude of an electromagnetic force applied to a locking device of the lock differential.

Description

Cross-references to related applications

[0001] This application was filed on April 22, 2024 as a PCT international application and claims the benefit and priority of U.S. Provisional Application No. 63 / 497,506, filed on April 21, 2023, the entire disclosure of which is incorporated herein by reference. Background Technology

[0002] Traction-modifying locking differentials typically include a gearbox defining a gear chamber, and a differential gear set disposed within the gear chamber, comprising at least one input pinion and a pair of output side gears. Typically, such a "locking differential" includes some form of locking mechanism to prevent rotation of one of the side gears relative to the gearbox; engagement of the locking mechanism is actuated by an actuator. Transmitting an appropriate input signal to an electromagnetic coil causes the locking member to engage the mating portion associated with the configured differential side gear. The electromagnetic coil is held by a stator disposed outside the gearbox. In some examples, bearing races hold the stator to the gearbox.

[0003] Reference Figure 9 An exemplary bearing race 162 radially supports and holds the stator 160 of the electromagnetic coil 116 at its outer periphery 150, positioning the stator 160 at the gearbox. The bearing race 162 (e.g., using a retaining ring) is secured to the gearbox. The bearing race 162 includes fingers 152 projecting radially outward from its outer periphery 150. The stator 160 defines a recess 154 at its axially outer portion 132. In some examples, the recess 154 is located at a radially inner corner of the stator 160. The fingers 152 of the bearing race 162 extend into the recess 154 to axially hold the stator 160 relative to the gearbox.

[0004] Magnetic flux density is mapped onto the stator 160, bearing race 162, and a portion 120 of the actuation mechanism for the locking member. When the solenoid coil 116 is energized, the notch 154 forms a “contraction point” for magnetic force to flow through the stator 160. For example, the magnetic flux density in the region of the stator 160 extending between the solenoid coil 116 and the notch 154 is higher than the magnetic flux density in the rest of the stator 160. The magnetic flux limits the magnitude of the magnetic force that can be applied between the stator 160 and the portion 120 of the actuation mechanism, which limits the stopping force of the locking differential 100.

[0005] The solution needs improvement. Summary of the Invention

[0006] According to certain aspects of this disclosure, a rotating device includes a stator that is axially movable relative to a rotatable housing. Bearing races limit the travel of the stator by engaging with an inner lip defined by the stator.

[0007] According to certain aspects of this disclosure, a rotating device includes a stator having an electromagnet that actuates a locking mechanism of the rotating device. The shape of the stator limits the magnetic flux density of the stator to less than 2 Tesla.

[0008] In some implementations, the stator defines a central opening extending between opposite first and second sides of the stator. The stator includes portions extending radially into the central opening to define an inner lip.

[0009] In some implementations, the stator thickness does not decrease from the radial outer end of the stator to the radial inner end of the stator.

[0010] The following description will set forth various additional aspects of the invention. These aspects may involve individual features and combinations of features. It should be understood that both the foregoing overview and the following detailed description are exemplary and illustrative only, and do not limit the broad inventive concept upon which the embodiments disclosed herein are based. Attached Figure Description

[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of this disclosure. A brief description of the drawings is as follows:

[0012] Figure 1 This is a cross-sectional view of an example locking differential constructed according to the principles of this disclosure;

[0013] Figure 2 It is applicable Figure 1 A three-dimensional view of an example stator of a locking differential;

[0014] Figure 3 yes Figure 2 A reverse stereoscopic view of the stator;

[0015] Figure 4 yes Figure 2 A cross-sectional view of the stator;

[0016] Figure 5 yes Figure 5 A magnified view of a portion of it;

[0017] Figure 6 yes Figure 2 An enlarged view of a portion of the image, showing the stator in a first position in which the electromagnetic coil is not energized;

[0018] Figure 7 yes Figure 2 An enlarged view of a portion of the image, showing the stator in a second position in which the electromagnetic coil is energized;

[0019] Figure 8 yes Figures 1 to 7The electromagnetic flux density diagram on the stator; and

[0020] Figure 9 It is an electromagnetic flux density diagram on a conventional inode. Detailed Implementation

[0021] Exemplary aspects of this disclosure will now be described in detail with reference to the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.

[0022] Figure 1 The locking differential 100 shown for a vehicle includes a gear housing 102 (e.g., a gearbox and end cap) configured to rotate about a longitudinal axis L of the housing 102. Torque input to the locking differential 100 can be provided to a flange 105 of the gear housing 102 via an input ring gear (not shown). The gear housing 102 defines annular hub portions 106 and 108, at which a left axle and a right axle are coupled. A pair of bearing assemblies (not shown) disposed at the annular hub portions 106, 108 provide rotational support for the rotating differential assembly 100 relative to an external differential housing or "carrier" (also not shown). The rotatable housing 102 defines a gear chamber in which a differential gear set 110 is disposed.

[0023] The locking differential 100 can operate in either a locked or unlocked mode. When operating in the locked mode, one or both side gears 126, 128 of the differential gear set 110 are locked to prevent rotation relative to the gear housing 102. When operating in the unlocked mode, the side gears 126, 128 are free to rotate relative to the gear housing 102. For example, the side gears 126, 128 may be configured to rotate independently about the longitudinal axis L of the gear housing 102. In some implementations, the locking differential 100 is manually switched between the locked and unlocked modes by the user. In other implementations, the locking differential 100 automatically switches between the locked and unlocked modes (e.g., by the vehicle's microprocessor based on sensed vehicle operating conditions).

[0024] The locking differential 100 includes a locking device 118 that can switch between a locked configuration and an unlocked configuration. When in the locked configuration, the locking device 118 prevents the side gear 126 from rotating independently relative to the gear housing 102. When in the unlocked configuration, the locking device 118 allows the side gear 126 to rotate independently relative to the gear housing 102.

[0025] In some implementations, a locking device 118 is disposed within the gear housing 102. The locking device 118 includes a generally annular collar member 122, which includes lugs extending outwardly from its periphery. When the locking device 118 is in a locked configuration, each lug is received within a mating, axially extending recess defined by the gear housing 102. The lugs prevent rotation of the collar member 122 relative to the gear housing 102, but allow axial movement of the collar member 122 between a locked position and an unlocked position. A biasing member 124 (e.g., one or more wave springs) biases the collar member 122 toward the unlocked position.

[0026] The locking device 118 also includes an actuation mechanism for switching the locking device 118 between a locked configuration and an unlocked configuration. The actuation mechanism includes an actuating member (e.g., a pin) extending outward from a fixed position at the collar member 122 and extending through the gear housing 102. The actuating member extends to a ramp plate 120 on the opposite side of the gear housing 102. In some examples, the ramp plate 120 is disposed outside the gear housing 102. The ramp plate 120 defines a plurality of ramp surfaces—one ramp surface 121 for each actuating member. When the actuating member is disposed at the bottom of the ramp surface 121, the biasing member 124 biases the collar member 122 to the unlocked position. As the ramp plate 120 rotates relative to the actuating member, the actuating member travels upward along the ramp surface 121, thereby axially pressing the collar member 120 to the locked position against the bias of the spring 124.

[0027] The rotation of the inclined plate 120 relative to the actuating member is controlled by an electromagnet 116 disposed at the stator 104. In some implementations, the inclined plate 120 is formed of an ferrous metal. When the electromagnet 116 is not energized (i.e., not actuated), the inclined plate 120 is driven by the actuating member to rotate together with the gear housing 102. When the electromagnet 116 is energized (i.e., actuated), the electromagnet 116 slows down the rotation of the inclined plate 120 relative to the gear housing 102. This slow rotation of the inclined plate 120 causes the actuating member to slide upward along the inclined surface 121 and causes the collar member 122 to shift to the locked position. In some implementations, the electromagnetic coil 116 may be energized by a pair of electrical leads (not shown).

[0028] Additional details regarding the function of the actuation mechanism of the locking differential 100 of the type described above are shown in U.S. Patent Nos. 6,083,134, 6,551,209, and 7,264,569, the disclosures of which are each incorporated herein by reference.

[0029] like Figure 1As shown, the stator 104 holding the electromagnet 116 is secured to the housing 102 using a bearing race 112. The bearing race 112 is mounted to the gear housing 102 in an axially fixed position. For example, the bearing race 112 can be axially secured to the gear housing 102 using a retaining ring 114. Other configurations are also possible. The abutment surface 144 of the bearing race 112 is aligned with the inner lip 140 of the stator 104 about the longitudinal axis L. In some implementations, the stator 104 is configured to be in a first position along the longitudinal axis L depending on whether the coil 116 is energized (e.g., see...). Figure 6 ) and the second position (for example, see Figure 7 The stator 104 travels axially between the inner lip 140 and the abutment surface 144 of the bearing race 112. The abutment between the first axial side of the stator 104 and the inclined plate 120 defines a second position.

[0030] Figures 2 to 5 The diagram illustrates the application in Figure 1 An example implementation of the stator 104 used in the locking differential 100. The stator 104 includes a body 130 extending between a first axial side 132 and a second axial side 134. The second axial side 134 defines a cavity (e.g., an annular cavity) 142 in which the coil 116 can be disposed. The body 130 defines a central opening 136 extending between the first axial side 132 and the second axial side 134. The central opening 136 allows the stator body 130 to be mounted around a portion of the housing 102 (e.g., see...). Figure 1 ).

[0031] According to certain aspects of this disclosure, the stator 104 includes a necking portion 138 that reduces the size of the central opening 136 at the second axial side 134 of the stator body 130. The necking portion 138 defines an inner lip 140 accessible within the central opening 136. In some implementations, the necking portion 138 is disposed at the second axial side 134 of the stator body 130. In some examples, the necking portion 138 is flush with the second axial side 134 of the stator body 104. In some implementations, the necking portion 138 extends along less than half the axial length of the stator body 130. In some implementations, the necking portion 138 extends along no more than one-quarter of the axial length of the stator body 130.

[0032] In some implementations, the central opening 136 of the stator body 130 has a first inner diameter ID1 at a first axial side 132 of the body 130 and a second inner diameter ID2 at a second axial side 134 of the body 130. In some implementations, the second inner diameter ID2 is smaller than the first inner diameter ID1. A necking portion 138 defines the second inner diameter ID2. In some implementations, the first inner diameter ID1 is constant between the inner lip 140 and the first axial side 132 of the stator body 130. In other implementations, the first inner diameter ID1 may vary between the inner lip 140 and the first axial side 132, but always remains larger than the second inner diameter ID2. In some implementations, the second inner diameter ID2 is constant at the necking portion 138.

[0033] In some implementations, the stator body 130 has a U-shaped cross-section (see, for example, see...). Figure 5 Cavity 142 is defined at the central portion of the U, while the bottom of the U forms the first axial side 132 of the stator body 130. In some implementations, the radially outer corner 146 of the U-shaped cross-section is profiled, while the radially inner corner 148 of the U-shaped cross-section is angled. In some implementations, the radially inner corner 148 has a square corner. In other implementations, the radially inner corner 148 is chamfered. In some implementations, the radially inner corner 148 is thicker than the radially outer corner 146.

[0034] The stator body 130 has a thickness T (see, for example, see...). Figure 5 The thickness T2 at the radially inner portion of the U-shaped cross-section is not less than the thickness T1 at the radially outer portion of the U-shaped cross-section. In some examples, the thickness T2 is greater than the thickness T1. In some examples, the thickness T of the stator body 130 does not decrease as the stator body 130 extends from the radially outer portion to the radially inner portion.

[0035] Figure 8 The magnetic flux density of the stator 104 configured according to the principles of this disclosure is shown. As illustrated, the stator 104 is not limited to notches for forming a compression point for electromagnetic flow (e.g., Figure 9 (The notch 154 of the stator 160). Conversely, the thickness T of the stator body 130 remains or increases as the body extends radially inward and then toward the ramp 120. Eliminating the constriction point increases the amount of electromagnetic force that can be applied to the ramp 120 by the coil 116. In some examples, increasing this force can help to counteract the rotational momentum of the ramp 120 more quickly and / or more effectively. In some examples, increasing this force allows for an increase in the biasing force of the spring 124, which can extend the life of the locking differential 100.

[0036] Preferred aspects and implementations of this disclosure have been described, and modifications and equivalents of the disclosed concepts will readily occur to those skilled in the art. However, such modifications and equivalents are intended to be included within the scope of the appended claims.

Claims

1. A rotating device, comprising: Rotatable housing; A stator, the stator including an annular housing disposed around a portion of the rotatable housing, the stator defining a central opening, a portion of the rotatable housing extending through the central opening when the stator is coupled to the rotatable housing, the stator including an inner lip extending radially from a radially inwardly facing periphery of the stator into the central opening; as well as A bearing race is mounted in a fixed position around the portion of the rotatable housing. The bearing race is sized to fit within the central opening of the stator, such that the outer periphery of the bearing race is opposite the radially inwardly facing periphery of the stator, wherein the inner lip of the stator extends radially inwardly beyond the outer periphery of the bearing race.

2. The rotating device according to claim 1, wherein, The abutting surface of the bearing race is located radially inside the outer periphery of the bearing race, and the abutting surface is aligned with the inner lip of the stator.

3. The rotating device according to claim 1, wherein, The bearing race has a constant outer diameter.

4. The rotating device according to claim 1, wherein, The bearing race does not have an outwardly extending lip.

5. The rotating device according to claim 1, wherein, The inner lip is located on the axial side of the stator.

6. The rotating device according to claim 2 further includes an electromagnet disposed at the stator.

7. The rotating device according to claim 6, wherein, The stator is configured to move axially from a first position to a second position relative to the housing when the electromagnet is activated, wherein the inner lip of the stator abuts against the abutting surface of the bearing race when in the first position, and the inner lip of the stator is spaced apart from the abutting surface of the bearing race when in the second position.

8. The rotating device according to claim 7, wherein, The stator is biased to the first position.

9. The rotating device of claim 8, further comprising a locking device mounted around the rotatable housing, the locking device being configured to switch between a locked configuration and an unlocked configuration, the locking device preventing rotation of the housing relative to the stator when configured in the locked configuration, and allowing rotation of the housing relative to the stator when configured in the unlocked configuration, the locking device selectively switching between the locked configuration and the unlocked configuration based on the activation of the electromagnet, wherein... The stator is biased to the first position via the locking device.

10. The rotating device according to claim 6, wherein, The stator defines an annular cavity, and the electromagnet is disposed in the annular cavity.

11. The rotating device according to claim 1, wherein, The thickness of the stator does not decrease from the radial outer end of the stator to the radial inner end of the stator.

12. A rotating device, comprising: Rotatable housing; A stator, the stator including an annular housing disposed around a portion of the rotatable housing, the stator defining a central opening through which a portion of the rotatable housing extends when the stator is coupled to the rotatable housing; as well as A bearing race is mounted at a fixed position around the portion of the rotatable housing. The bearing race is sized to fit within the central opening of the stator, such that the outer periphery of the bearing race is opposite the radially inward periphery of the stator, wherein the thickness of the stator does not decrease as the stator extends radially inward toward the outer periphery of the bearing race.

13. The rotating device according to claim 12, wherein, The axial engagement between the bearing race and the stator is located radially inside the outer periphery of the bearing race.

14. The rotating device according to claim 12, wherein, The bearing race has a constant outer diameter.

15. The rotating device according to claim 12, wherein, The bearing race does not have an outwardly extending lip.

16. The rotating device according to claim 12, wherein, The magnetic flux density of the entire stator is less than 2 Tesla.

17. The rotating device according to claim 12, wherein, The first side of the stator has no concave surface.

18. The rotating device according to claim 12, wherein, The diameter of the central opening at the second side of the stator is smaller than the diameter of the central opening at the first side of the stator.

19. A rotating device, comprising: Rotatable housing; A stator, the stator including an annular housing disposed around a portion of the rotatable housing, the stator defining a central opening, a portion of the rotatable housing extending through the central opening when the stator is coupled to the rotatable housing, the central opening extending between opposite first and second sides of the stator, the stator including a portion extending radially at the second side into the central opening to define an inner lip; A bearing race is mounted in a fixed position around the portion of the rotatable housing. The bearing race is sized to fit within the central opening of the stator, such that the abutting surface of the bearing race aligns with the inner lip of the stator to hold the stator to the rotatable housing.

20. The rotating device according to claim 19, wherein, The rotatable housing includes a differential housing.

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