Clutch assembly with lock plate

Abstract

A differential includes a case, a side gear, a lockup mechanism, and an engagement mechanism. The lockup mechanism includes a first lock plate having a first side and a toothed side, a second lock plate having a first side facing the case and a toothed second side facing the toothed side of the first lock plate, a cam plate axially between the side gear and the first lock plate, and a clutch assembly axially between the cam plate and the first lock plate. The engagement mechanism is configured to actuate rotation of the cam plate.

Description

[0001] This application is a divisional application of Chinese invention patent application filed on January 10, 2020, with application number 202080010597.1 and invention title "Clutch Assembly with Locking Plate".

[0002] This application claims priority to Indian Patent Application No. 201911001157, filed on January 10, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to clutch assemblies, and more specifically to clutch assemblies with locking plates used in, for example, mechanical locking differentials. Background Technology

[0004] When a predetermined traction condition is encountered (e.g., the wheel speed difference exceeds a predetermined value), a mechanical locking differential automatically locks. Mechanical locking differentials typically use a moving clutch assembly with numerous clutch discs to provide the required torque capacity from the ring gear to the wheels and to make the locking action smooth. Such a large number of clutch discs can result in an extended bearing span.

[0005] In some applications, it may be desirable to reduce the bearing span, which has a smaller axial width. However, reducing the number of clutch discs may be undesirable, as this could reduce torque capacity and thus prevent smooth locking action. Summary of the Invention

[0006] The apparatus and related methods disclosed herein overcome one or more of the aforementioned disadvantages and improve the art through the combination of a clutch assembly and a pair of locking plates.

[0007] For advantages and in accordance with the purposes of this disclosure, as embodied and broadly described herein, one aspect of this disclosure may provide a differential comprising: a housing; a side gear; a first locking plate including a first side and a toothed side; and a second locking plate including a first side facing the housing and a toothed second side facing the toothed side of the first locking plate. The differential may further comprise: a cam plate located between the side gear and the first locking plate; and a clutch assembly located between the cam plate and the first locking plate. The cam plate may include a spline neck extending toward the first locking plate, and the clutch assembly may include at least one movable clutch disc internally splined to the spline neck.

[0008] According to one embodiment, the side gear includes an external spline, and the internal spline of the first locking plate is connected to the external spline of the side gear. According to one embodiment, the housing further includes a guide groove, the second locking plate includes radially spaced external ears, and the ears are configured to be disposed in the guide groove formed in the housing. According to one embodiment, the housing further includes a guide groove, and the clutch assembly further includes at least one lug clutch disc, the at least one lug clutch disc including radially spaced external ears, and the ears of the at least one lug clutch disc being configured to be disposed in the guide groove formed in the housing. According to one embodiment, the at least one lug clutch disc includes two lug clutch discs, and the at least one movable clutch disc is disposed between the two lug clutch discs. According to one embodiment, the at least one lug clutch disc includes a friction material for clamping a first side of the first locking plate. According to one embodiment, the cam plate includes an external spline, and the cam plate is configured to be coupled to an actuator via the external spline. According to one embodiment, the differential further includes a disc spring disposed between the first locking plate and an inner wall of the housing.

[0009] Another exemplary aspect may provide a differential including: a housing including a guide recess; a side gear including an external spline; a first locking plate including an internal spline configured to engage the external spline of the side gear; and a second locking plate configured to engage the first locking plate. The differential may further include a cam plate including a neck extending from a side surface facing the first locking plate. The neck may include an external spline. The differential may further include a clutch assembly located between the cam plate and the first locking plate, wherein the clutch assembly may include: at least one first clutch disc having a lug configured to engage in a guide recess in the housing; and a second clutch disc with an internal spline connected to the external spline of the neck.

[0010] According to one embodiment, the at least one first clutch disc includes a pair of first clutch discs, and a second clutch disc is disposed between the pair of first clutch discs. According to one embodiment, the first locking plate includes a plurality of face teeth on its side surface facing the second locking plate, and the second locking plate includes a plurality of face teeth on its side surface facing the first locking plate, and the face teeth of the first locking plate are configured to engage with the face teeth of the first locking plate. According to one embodiment, the second locking plate includes a plurality of radially spaced outer ears, and the ears are configured to be disposed in guide grooves formed in the housing. According to one embodiment, the at least one first clutch disc includes a friction material for clamping the first locking plate. According to one embodiment, the cam plate includes an external spline, and the cam plate is configured to be coupled to an actuator via the external spline. According to one embodiment, the differential further includes a disc spring disposed between the first locking plate and an inner wall of the housing.

[0011] According to another exemplary aspect, a differential may include a housing including a first end and a second end opposite the first end; a first side gear including external splines; and a second side gear including external splines. The differential may further include: a first locking plate including a first side and a toothed side; a second locking plate including a first side facing the second end of the housing and a toothed second side facing the toothed side of the first locking plate; and a cam plate located between the side gear and the first locking plate. The cam plate may include a spline neck extending toward the first locking plate. The differential may further include: a first clutch assembly located between the cam plate and the first locking plate; and a second clutch assembly located between the first side gear and the first end of the housing. The first clutch assembly may include at least one movable clutch disc internally splined to the spline neck, and the second clutch assembly may include at least one movable clutch disc internally splined to the external splines of the first side gear.

[0012] According to one embodiment, the internal spline of the first locking plate is connected to the external spline of the first side gear. According to one embodiment, the housing includes a guide groove, the second locking plate includes radially spaced outer ears, and the ears are configured to be disposed in the guide groove formed in the housing. According to one embodiment, the clutch assembly further includes at least one lug clutch disc, the at least one lug clutch disc including radially spaced outer ears, and the ears being configured to be disposed in the guide groove formed in the housing. According to one embodiment, the at least one lug clutch disc includes two lug clutch discs, and the at least one movable clutch disc is disposed between the two lug clutch discs.

[0013] Other objects and advantages will be set forth in part in the description which follows, and in part will be obvious from the description or may become apparent through practice. These objects and advantages will also be achieved and attained by means of the elements and combinations particularly pointed out in the appended claims.

[0014] It should be understood that the foregoing general description and the following detailed description are merely exemplary and illustrative, and are not intended to limit the claimed invention. Attached Figure Description

[0015] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and, together with the specification, serve to explain the principles of the invention.

[0016] Figure 1 This is a perspective view of a mechanical differential.

[0017] Figure 2 yes Figure 1 A cross-sectional view of a mechanical differential.

[0018] Figure 3 yes Figure 2 A perspective view of the locking mechanism of a mechanical differential.

[0019] Figure 4A This is a plan view of the first side of the cam plate.

[0020] Figure 4B yes Figure 4A Side view of the cam plate.

[0021] Figure 4C yes Figure 4A A plan view of the second side of the cam plate opposite to the first side.

[0022] Figure 5 It is a plan view of a non-moving disk with a friction surface.

[0023] Figure 6 This is a plan view of the internal spline moving plate.

[0024] Figure 7A This is a plan view of the first side of the first locking plate.

[0025] Figure 7B yes Figure 7A A plan view of the second side of the first locking plate opposite to the first side.

[0026] Figure 8A This is a plan view of the first side of the second locking plate.

[0027] Figure 8B yes Figure 8A A plan view of the second side of the second locking plate opposite to the first side.

[0028] Figure 9A This is a cross-sectional view of a mechanical differential, showing an exemplary reaction block.

[0029] Figure 9B yes Figure 9A Plan view along plane 9C.

[0030] Figure 9C yes Figure 9A A perspective view of the reaction block. Detailed Implementation

[0031] Reference will now be made in detail to the exemplary embodiments shown in the accompanying drawings. Throughout the drawings, the same reference numerals will be used to denote the same or similar parts whenever possible. Directional reference numerals such as "left" and "right" are used for ease of reference to the drawings.

[0032] While exemplary embodiments of the invention will be described in conjunction with specific mechanical locking differentials, it should be understood that the invention can be applied to, or used in conjunction with, any other type of locking differential or any other suitable mechanical device that utilizes a clutch assembly.

[0033] Figure 1 and Figure 2 An example of a mechanical locking differential 1 is shown, which is configured to allow two wheels on a motor vehicle to operate at different speeds and maintain free differential action (i.e., unlocked mode). However, if one wheel begins to slip, the drive axle can automatically and fully lock left and right, causing the wheels to rotate at the same speed, thereby providing full power to both wheels (i.e., locked mode). Such mechanical locking differentials use mechanical, rather than electric or hydraulic, means to switch between locked and unlocked modes. In various exemplary embodiments, the mechanical means consistent with this disclosure may include one or more components described in U.S. Patent Nos. 6,319,166, 7,438,661, 8,167,763, and 9,400,044, which are assigned to Eaton Corporation and are incorporated herein by reference in their entirety.

[0034] The differential 1 may include a housing 5 configured to house the various components of the differential 1. Torque from the vehicle's powertrain may be transmitted to the differential 1 via an input gear (e.g., a ring gear) (not shown). The input gear may be integrally formed with or attached to the housing 5 by a suitable attachment mechanism (e.g., bolts). The input gear may engage with an input pinion (not shown) that receives input drive torque from the vehicle's powertrain.

[0035] The differential 1 may also include a differential gear set disposed within the housing 5. Specifically, the differential 1 may include two side gears 100, 200 (i.e., referred to hereinafter respectively as right-side gear 100 and left-side gear 200), a pinion shaft 60, and one or more pinions 62, 68 rotatably mounted on the pinion shaft 60. The pinion shaft 60 may be attached to the housing 5 and connected to the input pinion. The pinion shaft 60 may be a cylindrical rod, or as... Figures 9A to 9C As shown, a cross-shaft 160 may be used, which has a plurality of arms 175 corresponding to the number of pinions 162 mounted on the pinion shaft 160. It should be understood that any other suitable pinion shaft configuration known in the art may be used in addition to or alternatively.

[0036] Side gears 100 and 200 can spline engage with a pair of axles (not shown) of a motor vehicle. For example, each of the side gears 100 and 200 can have internal splines 120 and 220, and the corresponding axle can include a corresponding external spline (not shown), such that the torque of the side gears 100 and 200 can be transmitted to the corresponding axle.

[0037] Pinions 62 and 68 can mesh with side gears 100 and 200, allowing power transmitted from the engine to pinion shaft 60 to flow to the left and right axles. For example, when pinion shaft 60 rotates, pinions 62 and 68 can transmit differentiated or undifferentiated torque to the meshing side gears 100 and 200. The torque can then be transmitted to the respective axles via spline engagement between them, and to the wheels associated with those axles. Since this torque path, as well as rear-wheel drive (RWD) and all-wheel drive (AWD or 4WD) torque paths, are known, the vehicle powertrain is not shown. Although FWD, RWD, and AWD systems are specifically mentioned, it should be understood that the differential 1 of this disclosure can be used in any suitable environment requiring differential rotation of two axles.

[0038] During normal straight-line operation of the vehicle, limited differential movement may occur between the left and right axles (e.g., essentially no differential movement), and pinions 62 and 68 may not rotate relative to pinion shaft 60. Therefore, housing 5, pinions 62 and 68, side gears 100 and 200, and the axles all rotate as a single solid unit about the same axis of rotation of the axles. Under certain operating conditions, such as when the vehicle is turning, a certain amount of differential movement may occur between side gears 100 and 200 until a predetermined level of speed difference is reached (e.g., approximately 100 RPM difference between right-side gear 100 and left-side gear 200). Beyond this predetermined level, it may be desirable to delay the relative rotation between side gears 100 and 200 to prevent excessive differential movement between the axles.

[0039] To delay differential action between axles, the differential 1 may include a locking mechanism for locking the differential gear set and an actuator for actuating the locking mechanism. The locking mechanism may include a combination of a clutch assembly 40 and a pair of locking plates 1000, 2000 movably associated with a cam plate 300. Figures 4A to 4C As shown, the cam plate 300 may define a set of external teeth 310 extending from its radially outer surface. The cam plate 34 may also define a plurality of ramps 360 and a plurality of jaws 370 (e.g., protrusions) on a cam surface facing the left gear 200. The left gear 200 may also define a cam surface (i.e., the back face of the left gear 200) having a plurality of corresponding ramps 260 and a plurality of corresponding jaw receiving holes (not shown) machined into the cam surface. The ramps 260 on the left gear 200 may engage between corresponding ramps 360 on the cam plate 300. The holes on the cam surface of the left gear 200 prevent the cam plate 300 from tilting until a predetermined torque is applied at the external teeth 310 of the cam plate 300.

[0040] In some exemplary embodiments, the pawl 370 of the cam plate 300 and the corresponding hole of the left gear 200 are interchangeable. For example, the pawl 370 may be formed on the cam surface of the left gear 200, and the corresponding hole may be formed on the cam surface of the cam plate 300.

[0041] The cam plate 300 may also include a neck 330 extending from a side surface opposite to the cam surface. The neck 330 may include an external spline (e.g., teeth extending radially outward from the outer surface of the neck 330), such as... Figure 4B and Figure 4C As best shown in the diagram. One or both of the ramp 360 of the cam plate 300 and the ramp 260 of the left gear 200 may include a stepped transition or a smooth transition. Additionally, although in Figure 4A and 4B Four ramps 360 and 260 are shown, but more or fewer ramps may be used. Similarly, the corresponding holes of the pawl 370 of the cam plate 300 and / or the side gear 200 may be more or fewer than the four shown in the figures. The configuration of the cam plate 300 and the side gear 200 and their relationship can be further understood from examples described, for example, in U.S. Patents 3,606,803, 3,831,462, 5,484,347, 6,319,166, RE 28,004, 8,167,763, and 9,400,044, the entire contents of which are incorporated herein by reference.

[0042] To actuate the locking mechanism to lock differential 1, any suitable actuator known in the art can be used, such as those described in U.S. Patent Nos. 8,167,763 and 9,400,044. For example, such as Figure 1As shown, actuator 500 may include a combination of engagement mechanism 520 and locking mechanism 540. Engagement mechanism 520 may include a pair of spring-loaded hammers 525 on a first shaft that engages and rotates with the external teeth 310 of cam plate 300. When the first shaft rotates due to differential action and the rotational speed exceeds a predetermined value (e.g., a difference of approximately 100 RPM), the centrifugal force of the hammers 525 overcomes the spring force and causes them to swing out to engage the pawl 545 of locking mechanism 540 on a second shaft. One hammer 525 may be configured to engage the pawl 545 in one direction of rotation, while the other hammer 525 may be configured to engage the pawl 545 in the opposite direction. Locking between the hammers 525 and the pawl 545 generates a force applied to the external teeth 310 of cam plate 300, causing cam plate 300 to rotate out of the pawl position and into a tilt position, thereby initiating a locking mode. Since differential 1 may not lock at speeds above a predetermined speed (e.g., 20 mph), locking mechanism 540 may be configured to rotate pawl 545 away from engagement mechanism 520 when the vehicle is traveling at a speed exceeding the predetermined speed. Because the actuator 500 of this disclosure may be substantially similar to those described in the foregoing references, any additional details thereof are omitted herein.

[0043] Now for reference Figure 5 , Figure 6 , Figures 7A to 7B and Figures 8A to 8B This article describes a combination of clutch assembly 40 and a pair of locking plates 1000 and 2000 for use as a locking mechanism in, for example, a mechanical locking differential. Figure 2 As best shown, the locking mechanism of the differential 1 may include a pair of first locking plates 1000 and second locking plates 2000, which are associated with a left-side gear 2000 and a clutch assembly 40 disposed between the first locking plate 1000 and the cam plate 300. The locking mechanism may also include another clutch assembly 50 associated with the right-side gear 100.

[0044] The clutch assembly in a mechanical locking differential has two main functions: (1) to transmit the entire torque from the input gear (e.g., a ring gear) to the wheels of the vehicle when the differential is locked; and (2) to smooth the locking action through the slippage of the clutch itself. As will become apparent from the following description, when the locking plates 1000 and 2000 are used with the clutch assemblies 40 and 50 according to this disclosure, the total number of clutch discs required to maintain torque capacity can be reduced, which in turn reduces the bearing span. Therefore, conventional clutch assemblies can be replaced by a combination of reduced-size clutch assemblies 40 and 50 and locking plates 1000 and 2000 to reduce the bearing span.

[0045] refer to Figure 7A and Figure 7BThe first locking plate 1000 may include an internal spline 1050 (e.g., teeth on an inner radial surface) configured to engage with an external spline of the left-side gear 200. The first locking plate 1000 may also include a plurality of face teeth 1020 extending axially from a peripheral side surface facing the second locking plate 2000.

[0046] refer to Figure 8A and Figure 8B The second locking plate 2000 may include a ring having a plurality of face teeth 2010 extending axially from a side surface facing the first locking plate 1000. The face teeth 2010 of the second locking plate 2000 are sized and configured to mate with the face teeth 1020 of the first locking plate 1000. The second locking plate 2000 may also include a plurality of ears 2080 extending radially outward from its outer radial surface. The ears 2080 may engage with non-movable clutch discs 10, 30 (see...). Figure 5 The first locking plate 1000 and the second locking plate 2000 are fitted together into a guide groove 3 formed in the housing 5, so that the second locking plate 2000 can be locked without rotating relative to the inactive clutch discs 10, 30 and the housing 5. The size of the space between the first locking plate 1000 and the second locking plate 2000 can be set such that the ramp 360 of the cam plate 300 rests in the valley between the ramps 260 of the left gear 200 in the unlocked mode (e.g., open mode). This spacing can be selected such that when the cam plate 300 is locked, the ramp 360 of the cam plate 300 does not pass through the ramp 260 of the left gear 200. This design enables forced locking, allowing the differential 1 to operate in either fully locked or unlocked mode.

[0047] Locking plates 1000 and 2000 serve as forced locking elements, possessing high torque carrying capacity and low axial width. However, if locking plates 1000 and 2000 are used alone, the differential 1 may experience impact loads, and the vehicle may experience locking shocks. To prevent such locking shocks and achieve smooth locking action, the locking mechanism may employ a synchronizing mechanism including clutch assemblies 40 and 50 and disc spring 400. As the movable clutch discs exponentially increase the axial force acting on the clutch assemblies, movable clutch discs 80 and 20 may be used in clutch assemblies 50 and 40 of the right gear 100 and left gear 200, respectively, and each clutch assembly in clutch assemblies 40 and 50 uses a pair of ear-spline clutch discs 10, 30 and 70, 90 as non-movable clutch discs.

[0048] like Figure 5As shown, each inactive clutch disc 10, 30, 70, 90 may include a plurality of ears 12 extending radially outward from its outer radial surface. The ears 12 may be fitted into guide grooves 7 formed in the housing 5 using optional guide clips (not shown), such that the inactive clutch discs 10, 30, 70, 90 can rotate with the housing 5. In some exemplary embodiments, the guide groove 3 for receiving the ear 2080 of the locking plate 2000 and the guide groove 7 for receiving the ears 12 of the inactive clutch discs 10, 30 may be continuous or discontinuous, with or without stepped transitions to accommodate dimensional differences. Alternatively, the guide grooves 3 and 7 may be provided separately.

[0049] The movable clutch disc 20 may include a spline 25 (e.g., teeth on an inner radial surface) configured to engage an external spline on the neck 330 of the cam plate 300, allowing the movable clutch disc 20 to rotate with the cam plate 300. Similarly, the movable clutch disc 80 may be internally splined to an external spline of the right gear 100, allowing the movable clutch disc 80 to rotate with the right gear 100. Thus, on the right side of the differential 1, the non-movable clutch disc 90 engages the housing 5 on a first side and the movable clutch disc 80 on a second side. The non-movable clutch disc 70 engages the right gear 100 on a first side and the movable clutch disc 80 on a second side. On the left side of the differential 1, the non-movable clutch disc 30 engages the cam plate 300 on a first side and the movable clutch disc 20 on a second side. The non-movable clutch disc 10 engages the movable clutch disc 20 on a first side and the toothless side of the first locking plate 1000 on a second side. During differential 1 locking, the active clutch disc 20 moves along the external spline of the neck 330 of the cam plate 300 to engage the inactive clutch discs 10 and 30, and the active clutch disc 80 is movable along the external spline of the right-side gear 100 to engage the inactive clutch discs 70 and 90. At least the inactive discs 30 and 70 are movable such that the lug 12 can slide in the guide groove 3 of the housing 5. The two side gears 100 and 200 are then engaged by the clutch assemblies 50 and 40, respectively.

[0050] According to one exemplary aspect, such as 9A to Figure 9C As shown, the differential 2 may include a reaction block 600 configured to transmit force between the right-side gear 100 and the left-side gear 200. The reaction block 600 may also include... Figure 2 In the differential 1, clutch assemblies 40 and 50 are engaged and disengaged. In an exemplary embodiment disclosed in the invention, the differential 2 may use a cross shaft 160 having three evenly spaced arms 175 extending radially from a hub 170. The hub 170 may be an annular ring defining a central bore 165 configured to receive a reaction block 600, such as... Figure 9BAs best shown. The reaction block 600 can be a two-piece construction of the same thrust disk 610. For example, as Figure 9C As shown, the thrust disc 610 may have the shape of a limiting disc, with its central portion protruding outward to form a narrower neck portion 620. The neck portion 620 may be sized and constructed to fit within a central bore 165 of the cross shaft 160, and may define a through-hole 650 at its center. Figure 9A As shown, two thrust discs 610 can be arranged between the right gear 100 and the left gear 200, wherein their neck portions 620 are disposed within the central hole 165 of the cross shaft 160 and are adjacent to each other, and their wider flange portions 690 are adjacent to the respective side gears 100 and 2000.

[0051] It should be understood that any other suitable reactive block known in the art (such as the reactive block described in U.S. Patent No. 8,167,763) may alternatively be used to transmit force between the right gear 100 and the left gear 200 in differential 1 or differential 2. For example, the reactive block may be configured to provide an axial link between the right gear 100 and the left gear 200. In differential 1, force from the left gear 200 can be transmitted via the reactive block to the right gear 100, which transmits the force to the clutch assembly 50. Similarly, force from the right gear 100 can be transmitted via the reactive block to the left gear 200, which transmits the force to the clutch assembly 40. Thus, the reactive block enables limited-slip operation.

[0052] In some exemplary embodiments, the reaction block can be omitted from the differential 2. For example, the size of the differential 2 allows a non-movable clutch disc from clutch assembly 50 to be placed on the right gear 100, so that clutch assembly 40 is placed on the left gear 200. This results in a combination of clutch assembly 40 and clutch assembly 50. One of the movable discs 30, 70 can be omitted while keeping the total number of movable clutch discs 20, 80 the same. In these cases, the combined clutch assembly 40+50 is located on one side of the differential 2, the right-hand clutch assembly is not used, and the reaction block can be omitted. This provides a smaller and lighter differential.

[0053] Since the toothless side of the locking plate 2000 engages with the non-movable clutch disc 10, an additional friction surface can be provided between the cam plate 300 and the locking plates 1000, 2000. Similarly, an additional friction surface can be provided between the cam plate 300 and the non-movable clutch disc 30. In one exemplary embodiment, a friction surface can be provided on the toothless side of the locking plate 1000, on the side of the cam plate 300 facing the non-movable clutch disc 30, or both. The friction surface may include, for example, a knurled pattern on a metal surface. In another embodiment, the friction surface can be provided by treating the surface or by applying a friction material. For example, as... Figure 5 As shown, the non-movable clutch discs 10, 30, 70, and 90 may be provided with a carbon friction material applied to the metal surface. Depending on the application, the movable clutch discs 20 and 80 may also be untreated or provided with friction surfaces. Differential locking and the transmission of torque via friction can be smoothly enhanced in a smaller footprint.

[0054] The synchronization mechanism may also include a coil spring 400 (such as a Basswell washer, for example) disposed between the locking plates 1000, 2000 and the inner wall of the housing 5. Since the engagement of the locking plates 1000 and 2000 requires axial movement, a reaction force is needed to counteract the tilting of the cam plate 300. The coil spring 400 can deflect and generate a spring reaction force, with a small or limited deflection toward the locking plates 1000 and 2000, to counteract the tilting of the cam plate 300.

[0055] While the various operating characteristics of the clutch assemblies 40 and 50 with locking plates 1000 and 2000 are readily apparent from the above description, some exemplary operating characteristics will be briefly described herein. During normal straight-line operation of the motor vehicle (e.g., when little or no differential action occurs), the cam surface of the left gear 200 and the cam surface of the cam plate 300 remain in an intermediate position (i.e., without tilting), wherein the cam plate 300 rotates together with the side gear 200 at the same rotational speed.

[0056] Under certain operating conditions (e.g., a rotational speed difference between side gear 100 and side gear 200 exceeding approximately 100 RPM), actuator 500 may apply torque to the external teeth 310 of cam plate 300. Applying torque to the external teeth 310 exceeding a predetermined level delays the rotation of cam plate 300 relative to left gear 200 and causes tilting of the cam surface of cam plate 300 and the cam surface of left gear 200.

[0057] The tilting of the cam plate 300 causes it to move axially away from the left gear 200 and toward the clutch assembly 40 and the locking plates 1000 and 2000. Simultaneously, in response to the tilting of the cam plate 300, the disc spring 400 deflects and generates a very high axial reaction force to counteract the force applied by the cam plate 300. Due to the axial reaction force, the axial movement of the cam plate 300 can apply pressure to the clutch assembly 40. The pressure applied to the clutch assembly 40 results in engagement between the moving disc 20 and the non-moving discs 10 and 30 (e.g., a "loaded" state). Because the moving disc 20 engages with the external spline on the neck 330 of the cam plate 300, the clutch assembly 40 in the loaded state causes a reduction in the speed difference between the left gear 200 and the housing 5.

[0058] When the disc spring 400 deflects by a certain amount, it generates sufficient axial force to reduce the speed difference between the first locking plate 1000 and the second locking plate 2000 to a level where they can engage with each other, thereby achieving complete locking of the differential 1. For example, this axial force causes the first locking plate 1000 and the second locking plate 2000 to move axially toward each other, such that the face teeth 1020 of the first locking plate 1000 engage and lock with the face teeth 2010 of the second locking plate 2000. Since the first locking plate 1000 engages with the external spline of the side gear 200, and the second locking plate 2000 is locked to the housing 5 via the lug 2080 fitted into the guide groove 3 of the housing 5, the locking between the first locking plate 1000 and the second locking plate 2000 effectively prevents relative rotation between the housing 5 and the side gear 2000, thereby delaying the differential action between the side gears 100 and 200.

[0059] For unlocking, when the left gear 200 experiences torque reversal due to the gap between the clutch assembly 40 and the locking plate 1000 relative to the left gear 200, the side gear 200 rotates in the opposite direction to the locking direction. Simultaneously, the cam plate 300 rotates together with the left gear 200. This reduces the axial force provided by the disc spring 400 and causes the locking plates 1000 and 2000 to disengage from each other.

[0060] Other implementations will become apparent to those skilled in the art upon consideration of the specification and practice of the examples disclosed herein.

Claims

1. A differential, the differential comprising: case; Side gear; The locking mechanism includes: A first locking plate, the first locking plate including a first side and a toothed side; The second locking plate includes a first side facing the housing and a toothed second side facing the toothed side of the first locking plate; A cam plate, the cam plate being axially located between the side gear and the first locking plate; and A clutch assembly, the clutch assembly being axially located between the cam plate and the first locking plate; A coil spring, disposed between the first and second locking plates and the inner wall of the housing, wherein a portion of the coil spring extends abuts against the inner wall of the housing; and A coupling mechanism configured to actuate the cam plate to rotate. The clutch assembly includes a plurality of clutch discs, the plurality of clutch discs including at least one clutch disc rotatably coupled to the cam plate, and The rotation of the cam plate causes it to move axially away from the side gear to apply an axial force to the clutch assembly.

2. The differential of claim 1, wherein the engagement mechanism comprises a pair of spring-loaded flyweights on a first shaft, the first shaft meshing with and rotating with the external teeth of the cam plate.

3. The differential of claim 2, wherein the pair of flyweights are configured to engage the pawls of the locking mechanism disposed on the second shaft.

4. The differential of claim 3, wherein one of the pair of fly hammers is configured to engage the pawl in a first rotational direction, and the other of the pair of fly hammers is configured to engage the pawl in an opposite second direction.

5. The differential according to claim 1, wherein the disc spring is a Bavarian washer.

6. The differential of claim 1, wherein the disc spring is configured to generate sufficient axial force to reduce the speed difference between the first locking plate and the second locking plate to a level at which they can engage with each other.

7. The differential of claim 1, wherein the differential further comprises a pinion shaft and one or more pinions rotatably mounted on the pinion shaft.

8. The differential of claim 7, wherein the pinion shaft is attached to the housing, wherein the one or more pinions mesh with the side gear and are configured to transmit differentiated or undifferentiated torque to the meshing side gear.

9. The differential according to claim 7, wherein the pinion shaft is a cylindrical rod.

10. The differential of claim 7, wherein the pinion shaft is a cross shaft having a plurality of arms corresponding to the number of pinions mounted on the cross shaft.

11. A differential, the differential comprising: case; Side gear; The locking mechanism includes: A first locking plate, the first locking plate including a first side and a toothed side; The second locking plate includes a first side facing the housing and a toothed second side facing the toothed side of the first locking plate; A cam plate, the cam plate being axially located between the side gear and the first locking plate; and A clutch assembly, the clutch assembly being axially located between the cam plate and the first locking plate; A coil spring, disposed between the first and second locking plates and the inner wall of the housing, wherein a portion of the coil spring extends abuts against the inner wall of the housing; and A cross shaft is attached to the housing, the cross shaft having a plurality of arms extending radially from the hub, the number of the plurality of arms corresponding to the number of pinions mounted on the cross shaft. The clutch assembly includes a plurality of clutch discs, the plurality of clutch discs including at least one clutch disc rotatably coupled to the cam plate, and The rotation of the cam plate causes it to move axially away from the side gear to apply an axial force to the clutch assembly.

12. The differential of claim 11, wherein the crossshaft comprises three evenly spaced arms.

13. The differential of claim 11, wherein the differential further comprises a reaction block configured to transmit force between a right-side gear and a left-side gear of the differential, wherein the hub is an annular ring defining a central bore configured to receive the reaction block.

14. The differential of claim 13, wherein the reaction block is a two-piece construction of the same thrust plate, the central portion of the thrust plate projecting outward to form a narrower neck portion, the neck portion being configured to be disposed within the central bore.

15. The differential of claim 14, wherein the thrust plate includes a wider flange portion connected to the neck portion and configured to abut the side gear.

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