System and method for coupling a locking plate and an actuator

Abstract

A lockable differential assembly includes a locking plate rotatable about an axis of rotation. The differential assembly also includes an actuator assembly having a stator and an armature, the actuator assembly being switchable between a powered-on state and a powered-off state. A slip ring assembly is also provided that is configured to translate axially based on the differential assembly being in the locked state or the unlocked state and that includes a slip ring that engages the armature at a sliding surface and one or more pins that rotationally lock the slip ring to the locking plate. The slip ring assembly is also configured to transmit an axial locking force and an axial restoring force between the actuator assembly and the locking plate.

Description

[0001] priority

[0002] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 63 / 400,615, filed on August 24, 2022, and claims the benefit under 35 U.S.C. §119(a) of Indian Provisional Patent Application No. 202211048231, filed on August 24, 2022, the entire contents of both patent applications are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to vehicle driveline systems and, more particularly, to systems, apparatus, and methods for a lockable differential assembly. Background Art

[0004] A vehicle differential assembly is a torque control device that enables the axles to operate at different rotational speeds, such as when the vehicle is turning. A lockable differential assembly enables the axles to be constrained or locked to operate at the same rotational speed, such as in low-traction road conditions. An electronically lockable differential assembly enables a user to selectively enable or disable the locking function through an electronic actuation device (e.g., by using a switch, button, or other user interface element in the vehicle).

[0005] Increasingly challenging packaging constraints, safety requirements and reliability targets drive design improvements in electronic locking differential assemblies. Electric vehicle-specific considerations further drive innovation in design, packaging and vehicle integration.

[0006] The description provided here is to generally present the context of the present disclosure. To the extent described in this section, the work of the presently named inventors and various aspects of the description that were not considered prior art at the time of filing are neither explicitly nor implicitly admitted to be prior art to the present disclosure. Summary of the invention

[0007] In a particular embodiment, a lockable differential assembly is disclosed, the differential assembly including a locking plate rotatable about a rotational axis, wherein the differential assembly is configured to be in a locked state or an unlocked state based on selective axial engagement of the locking plate relative to a locking gear; an actuator assembly including a stator and an armature, the actuator assembly being configured to switch between an energized state and a de-energized state; and a slip ring assembly configured to translate axially corresponding to the locked state or the unlocked state of the differential assembly, and the slip ring assembly including: a slip ring that engages the armature at a sliding surface, and the sliding surface is configured to allow relative rotation between the slip ring and the armature; and one or more pins that rotationally couple the slip ring to the locking plate, wherein the slip ring assembly is configured to transmit an axial locking force from the actuator assembly to the locking plate when the actuator assembly is energized, and wherein the slip ring assembly is configured to transmit an axial reset force from the locking plate to the actuator assembly when the actuator assembly is de-energized.

[0008] In a specific embodiment that may combine the features of some or all of the above embodiments, the differential assembly further comprises a lock detection sensor assembly, the lock detection sensor assembly comprising a sensor and a target, the lock detection sensor assembly being configured to detect the axial distance between the stator and the armature. In a specific embodiment that may combine the features of some or all of the above embodiments, one of the sensor and the target is coupled to the armature, and the other of the sensor and the target is coupled to the stator.

[0009] In a specific embodiment that may combine the features of some or all of the above-described embodiments, the differential assembly further includes an anti-rotation assembly comprising: a first connecting member that couples a sensor of the lock detection sensor assembly to a stator housing of the actuator assembly; and a second connecting member that couples a target of the lock detection sensor assembly to an armature, wherein the first connecting member or the second connecting member comprises one or more extension structures configured to constrain the armature in a fixed rotational position relative to the stator.

[0010] In a specific embodiment that can combine the features of some or all of the above-mentioned embodiments, the lock detection sensor assembly detects the axial distance between the stator and the armature based on detecting the magnetic field strength, wherein the slip ring is symmetrical about a longitudinal plane passing through the rotation axis and the lock detection sensor assembly to facilitate improving the accuracy of lock detection.

[0011] In a specific embodiment that can combine the features of some or all of the above embodiments, the lock detection sensor assembly detects the axial distance between the stator and the armature based on the detection of the magnetic field strength, wherein one or more pins are symmetrically distributed around the rotation axis to facilitate improving the accuracy of the lock detection. In a specific embodiment that can combine the features of some or all of the above embodiments, the stator includes a stator coil, wherein energizing the actuator assembly includes causing current to flow through the stator coil to generate a magnetic field, and wherein the armature is subjected to a magnetic force toward the stator coil based on the magnetic field generated when the actuator assembly is energized.

[0012] In a specific embodiment that can combine the features of some or all of the above embodiments, the slip ring is configured to focus the magnetic field generated by the actuator assembly when it is in the energized state through the air gap between the armature and the stator, so as to facilitate improving the efficiency of the actuator assembly when actuating the locked state of the differential assembly. In a specific embodiment that can combine the features of some or all of the above embodiments, the slip ring includes at least one axial groove to allow the flow of hydraulic fluid and help reduce the hydraulic damping generated when the slip ring assembly translates axially.

[0013] In a specific embodiment that may combine the features of some or all of the above-described embodiments, the slip ring includes, for each of the one or more pins, a hole having a hole diameter and configured to receive the corresponding pin; and a slot configured to facilitate entry of the corresponding pin, wherein the slot width of the slot has a value between the hole diameter and ten times the hole diameter.

[0014] In a particular embodiment, which may combine features of some or all of the above described embodiments, the slip ring is configured to align the armature radially with respect to the rotation axis. In a particular embodiment, which may combine features of some or all of the above described embodiments, the slip ring is configured to align the stator radially with respect to the rotation axis.

[0015] In a specific embodiment in which the features of some or all of the above-described embodiments may be combined, the slip ring assembly further comprises one or more features for axially constraining the armature relative to the slip ring. In a specific embodiment in which the features of some or all of the above-described embodiments may be combined, the slip ring assembly further comprises one or more features for axially constraining the slip ring relative to one or more pins.

[0016] In a specific embodiment that may combine the features of some or all of the above-described embodiments, the one or more features comprise a groove or a raised edge provided in the slip ring or in one or more pins. In a specific embodiment that may combine the features of some or all of the above-described embodiments, the one or more features comprise a washer, a snap ring or an e-clip. In a specific embodiment that may combine the features of some or all of the above-described embodiments, one or more of the pins are press-fit into the locking plate.

[0017] In a specific embodiment, the differential assembly includes a differential housing; a locking gear rotatably disposed in the differential housing; a locking plate rotatable about a rotation axis, wherein the differential assembly is configured to be in a locked state or an unlocked state based on selective axial engagement of the locking plate relative to the locking gear; a biasing member configured to axially bias the locking gear away from the locking plate; an actuator assembly including a stator and an armature, and the actuator assembly is configured to switch between an energized state and an unenergized state; a lock detection sensor assembly including a sensor and a target, and the lock detection sensor assembly is configured to detect the stator. an axial distance between the differential assembly and the armature; and a slip ring assembly configured to translate axially corresponding to a locked state or an unlocked state of the differential assembly, and the slip ring assembly includes: a slip ring engaged with the armature at a sliding surface, and the sliding surface is configured to allow relative rotation between the slip ring and the armature; and one or more pins rotationally locking the slip ring to a locking plate, wherein the slip ring assembly is configured to transmit an axial locking force from the actuator assembly to the locking plate when the actuator assembly is energized, and wherein the slip ring assembly is configured to transmit an axial reset force from the locking plate to the actuator assembly when the actuator assembly is de-energized.

[0018] In a particular embodiment, which may combine features of some or all of the above-described embodiments, the slip ring comprises at least one axial groove to allow the flow of hydraulic fluid and to help reduce hydraulic damping generated when the slip ring assembly translates axially.

[0019] In a specific embodiment, the devices, systems and techniques described herein relate to a method for assembling a lockable differential assembly, the method comprising: providing a locking gear and a locking plate in a differential housing, the locking gear and the locking plate being selectively engageable by relative axial translation, the locking gear and the locking plate being axially biased apart by a biasing member and being rotatable about a rotation axis; rotationally locking the locking plate to a slip ring via one or more pins, the slip ring assembly comprising a slip ring and one or more pins; providing an actuator assembly, the actuator assembly comprising a stator and an armature, the slip ring being axially locked to the armature (axially locked to the armature); couple, axial connection), and the sliding interface between the slip ring and the armature is configured to allow relative rotation between the slip ring and the armature, wherein the armature is configured to translate axially toward the stator based on energizing the actuator assembly; and providing a lock detection sensor assembly, the lock detection sensor assembly includes at least one sensor component respectively coupled to each of the armature and the stator, and the lock detection sensor assembly is configured to detect the axial distance between the stator and the armature, wherein the slip ring assembly is configured to transmit an axial locking force from the actuator assembly to the locking plate when the actuator assembly is energized, and wherein the slip ring assembly is configured to transmit an axial reset force from the locking plate to the actuator assembly when the actuator assembly is de-energized. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present disclosure will be described in more detail below based on exemplary drawings. The present disclosure is not limited to these exemplary embodiments. Other features and advantages of various embodiments of the present disclosure will become apparent by reading the following detailed description with reference to the accompanying drawings, which show the following:

[0021] Figure 1 A schematic side cross-sectional view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0022] Figure 2 A schematic front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0023] Figure 3 A schematic side cross-sectional view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0024] Figure 4 A schematic enlarged front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0025] Figure 5 A schematic enlarged side cross-sectional view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0026] Fig. 6A and Figure 6BA schematic enlarged side cross-sectional view of a particular exemplary embodiment of an electronic locking differential assembly is shown, illustrating various design features.

[0027] Fig. 7A and Figure 7B A schematic enlarged side cross-sectional view of a particular exemplary embodiment of an electronic locking differential assembly is shown with design features depicted and contrasted.

[0028] Fig. 8A A schematic front perspective view of a slip ring according to certain embodiments is shown.

[0029] Figure 8B A schematic front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0030] Figure 8C A schematic front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0031] Fig. 9 A schematic front perspective view of an electronic locking differential assembly assembled within an axle housing is shown according to certain embodiments, wherein the axle housing is shown cut away.

[0032] Fig.10 A schematic front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0033] Fig.11 A schematic enlarged front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0034] Fig. 12A A schematic enlarged front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0035] Fig. 12B A schematic enlarged front perspective view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0036] Fig. 12C A schematic side cross-sectional view of an electronic locking differential assembly is shown in accordance with certain embodiments.

[0037] Fig.12D A schematic side cross-sectional perspective view of an electronic locking differential assembly is shown according to certain embodiments.

[0038] It should be noted that the drawings provided may be shown schematically rather than realistically or precisely; the various components and aspects in the drawings may not necessarily be drawn to scale. In addition, although in many cases the same reference numerals may represent corresponding components in different views, the same components may not always have the same reference numerals in each view. DETAILED DESCRIPTION

[0039] According to various embodiments of the present disclosure, various mechanisms, components, arrangements, and methods of operation, manufacturing, and / or assembly of vehicle transmission systems, lockable differential assemblies, and / or related subsystems are disclosed herein. For clarity, although specific aspects will be described and / or illustrated to provide a better understanding, all features of each embodiment may not be described in this specification.

[0040] With reference to the accompanying drawings, Figure 1 A schematic side cross-sectional view of an electronically locking differential assembly according to a particular embodiment is shown. In a particular embodiment, the lockable differential assembly 110 can include a locking plate 140 that can rotate about an axis of rotation within the differential case 130. In a particular embodiment, the differential assembly 110 can be configured to be in a locked state or an unlocked state based on a relative axial position of the locking plate 140 and / or a selective axial engagement of the locking plate 140 relative to the locking gear 135.

[0041] As an example and not limitation, in the absence of an applied locking force, the locking plate 140 may be biased, such as mechanically biased by a return spring, to maintain the differential assembly 110 in an unlocked state in which the locking plate 140 may be disengaged from the locking gear 135 and the axle 120 may be free to rotate at different rotational speeds. In certain embodiments, a return spring force (such as a return spring force due to the return spring 150) may act on the locking plate 140 (in the unlocked state). Figure 1 In a specific embodiment, if a sufficient locking force is applied to the locking plate 140 to make it overcome the return spring force and translate axially to the right (also in the reference frame of FIG. Figure 1 ), the differential assembly 110 may be placed in a locked state in which the axles 120 may be constrained to rotate at the same rotational speed.

[0042] Continue to refer Figure 1In certain embodiments, electronic locking of the differential assembly 110 may be achieved using an actuator assembly, such as an electronic actuator assembly 210, which may include an armature 220 and a stator 230 having stator coils 234. In certain embodiments, the electronic actuator assembly 210 may be configured to switch between an energized state and a de-energized state.

[0043] Figure 2 A schematic front perspective view of an electronic locking differential assembly according to certain embodiments is shown. Figure 2 , in particular embodiments, the armature 220 and the stator coils 234 (located within the stator housing 232) can be generally annular components that can be positioned concentric with the axis of rotation of the differential assembly 110. In particular embodiments, as will be further discussed herein, the armature 220 and / or the stator coils 234 may need to be constrained and / or guided along one or more axes to occupy or remain in a particular configuration and / or position. In particular embodiments, the stator housing 232 may include one or more electrical leads 240 for supplying current to energize the stator coils 234 and / or conduits for guiding the electrical leads 240. In particular embodiments, the electrical leads 240 can be connected to the vehicle electrical system, such as by a wiring harness.

[0044] In certain embodiments, the electric actuator assembly 210 can be powered on and / or off. As an example and not limitation, powering the electric actuator assembly 210 can include passing current through the stator coil 234 to generate a magnetic field, and the armature 220 can experience a magnetic force toward the stator coil 234 based on the magnetic field generated when the electric actuator assembly 210 is powered on.

[0045] As an example and not limitation, when the stator coil 234 is energized, the armature 220 may be subjected to an electromagnetic attraction force toward the stator coil 234 sufficient to cause the armature 220 to translate axially (in Figure 1 Corresponding to this axial translation, the armature 220 may apply a rightward axial force, such as through a slip ring 320 and / or one or more transfer pins 340, which in turn may apply a force to the locking plate 140 (in Figure 1 In certain embodiments, such axial force applied directly or indirectly by the electronic actuator assembly 210 on the locking plate 140 to place the differential assembly 110 in the locked state may be opposed by a return force such as provided by a biasing member (e.g., return spring 150).

[0046] In certain embodiments but not limited thereto, the transfer pin 340 may be referred to as a push pin, an indexing pin, or simply a pin.

[0047] During normal operation of the differential assembly 110, various components of the differential assembly 110 may rotate about the axis of rotation of the differential assembly 110. In certain embodiments, as a non-limiting example, certain components that may be rotationally stationary relative to a rotating component may include one or more components of the electronic actuator assembly 210 (including a stator 230 and / or an armature 220, the stator including a stator coil 234 located in a stator housing 232). As an example and not limitation, other components that may be rotationally stationary in some embodiments, either alone or in addition, may include a lock detection sensor assembly 410 (the lock detection sensor assembly further including a lock detection sensor 420 and a sensor target 430). In certain embodiments, one or more of these components may be constrained to remain rotationally stationary relative to the rotating component of the differential assembly 110 based on a mechanical coupling to a rotationally stationary vehicle structure and / or to each other. As an example and not limitation, an axle housing 510 (e.g., such as a wheel axle housing 510) may be constrained to remain rotationally stationary relative to the rotating component of the differential assembly 110 based on a mechanical coupling to a rotationally stationary vehicle structure and / or to each other. Fig. 9 ) may provide a rotationally stationary anchoring structure or reference frame to constrain certain components of the differential assembly 110 to remain rotationally stationary relative to rotating components.

[0048] In certain embodiments (by way of example and not limitation), Figure 3 and Figure 4 ), the armature 220 can be directly engaged with one or more transfer pins 340 (i.e., without an intermediate slip ring, which will be discussed further herein), wherein the engagement can be configured to transmit axial force and / or axial translation between each transfer pin 340 and the armature 220. In certain embodiments, the armature 220 can be additionally or separately constrained in the axial direction, such as using washers 239. Figure 3 and Figure 4 The embodiment shown in FIG. 3 may include three transfer pins 340. Alternative designs are possible, such as having a different number of transfer pins 340.

[0049] The differential assembly 110 in certain embodiments may have a relatively limited reaction surface between the armature 220 and the transfer pin 340. In certain embodiments, the transfer pin 340 may be asymmetrically distributed and / or the transfer pin may contain materials that may interfere with sensitive magnetic sensing devices (such as lock detection sensor assemblies) associated with the differential assembly 110. In certain embodiments, unexpected changes in the magnetic field (such as changes based on relative rotation of the components) may hinder the accurate and / or precise use of the magnetic sensing device. Other details and aspects related to the lock detection sensor are further discussed herein.

[0050] In certain embodiments, the slip ring assembly 310 may be configured to translate axially in response to a locked state or an unlocked state of the differential assembly 110. In certain embodiments, the slip ring assembly 310 may include a slip ring 320.

[0051] In certain embodiments, the slip ring assembly 310 can be configured to transmit an axial locking force from the electric actuator assembly 210 to the locking plate 140 when the electric actuator assembly 210 is powered. As an example and not limitation, when the electric actuator assembly 210 is powered, the axial locking force can be generated based on the armature 220 being subjected to a magnetic force toward the stator coil 234.

[0052] In certain embodiments, the slip ring assembly 310 can be configured to transmit an axial reset force from the locking plate 140 to the electronic actuator assembly 210 when the electronic actuator assembly 210 is de-energized. As an example and not limitation, the axial reset force can be based on a force for separating the locking plate 140 from the locking gear 135 and / or for axially translating the locking plate 140 away from the locking gear 135 and toward the electronic actuator assembly 210 (i.e., in the case of a Figure 1 The restoring force or restoring force is a return force or a restoring force that is a translation toward the left in the reference frame of the object.

[0053] In certain embodiments, the slip ring 320 may engage the armature 220 at a sliding surface configured to allow relative rotation between the slip ring 320 and the armature 220. As an example and not limitation, the slip ring 320 may be made of a different material than the adjacent surface, such as brass and / or other metallic or non-metallic materials.

[0054] In certain embodiments, the slip ring 320 can be configured to focus the magnetic field and / or enhance the magnetic flux generated when the electronic actuator assembly 210 is in the energized state, for example, through the air gap between the armature 220 and the stator 230. In certain embodiments, the slip ring 320 can be configured alone or additionally to minimize the magnetic losses of the hub. As an example and not limitation, in certain embodiments, the slip ring 320 can focus, shape, guide and / or constrain the magnetic field lines between the armature / stator gap radially outside the slip ring 320. As an example and not limitation, in certain embodiments, the slip ring 320 can focus, shape, guide and / or constrain the magnetic field lines to minimize the magnetic losses of the hub and / or the differential housing 130 radially inside the slip ring 320. In certain embodiments, the slip ring 320 can be configured alone or additionally to optimize the magnetic field in the axial direction to maximize the magnetic pull acting on the armature 220 when the electronic actuator assembly 210 is energized.

[0055] By way of example and not limitation, configuring the slip ring 320 to focus the magnetic field and / or minimize magnetic losses in the hub and / or other components of the differential assembly 110 may be advantageous in increasing the efficiency of the energy requirements of the electronic actuator assembly 210 in actuating a locked state of the differential assembly 110. Thus, in certain embodiments, a smaller, lighter, and / or lower power electronic actuator assembly 210 may be used to actuate the locked state.

[0056] In certain embodiments, the geometry, materials, and / or manufacturing methods of the slip ring 320 may take into account one or more of the following factors: (a) load bearing requirements for axial and / or radial alignment and / or restraint of specific engaging parts; (b) friction requirements for relative sliding of specific engaging parts; (c) fatigue, hardness, and / or other structural requirements for service life, such as no need for replacement; (d) magnetic properties, such as for shaping, restraint, guidance, and / or reduction of magnetic losses. As an example and not limitation, Fig. 8A The geometric features of specific embodiments that meet these requirements are depicted and disclosed.

[0057] In a particular embodiment, a slip ring 320 including one or more of the desirable performance features disclosed herein may be manufactured using a suitable method. As an example and not limitation, the slip ring 320 may be made of a powder or sintered blank, and optionally subsequently fine-machined. In a particular embodiment, one or more non-magnetic materials may be used to manufacture the slip ring 320. In a particular embodiment, one or more materials for manufacturing the slip ring 320 may be selected based on the magnetic properties of the material to reduce magnetic losses. In a particular embodiment, one or more materials for manufacturing the slip ring 320 may be selected based at least on the magnetic permeability properties of the material to shape, guide, focus, and / or otherwise interact with the magnetic field within the magnetic field influence range of the slip ring 320.

[0058] In certain embodiments, the slip ring 320 can be rotationally locked to the locking plate 140 using one or more transfer pins 340. In certain embodiments, the one or more transfer pins 340 can be press fit into the locking plate 140.

[0059] In certain embodiments, such as Figure 5As depicted in the drawings, a slip ring 320 may be used between the armature 220 and one or more transfer pins 340, wherein the engagement of the armature 220 and the slip ring 320 may be configured to achieve one or more of the following: (i) relative rotational movement (sliding) between the armature 220 and the slip ring 320 so that the armature 220 can remain rotationally stationary relative to the rotating components of the differential assembly 110; (ii) transmitting axial forces and / or axial translations between the armature 220 and the slip ring 320 in one or more axial motion directions; and (iii) more rigidly constraining the armature 220 to move with the locking plate 140 and / or the transfer pin 340 in an axially corresponding manner.

[0060] With such as Figure 3 and Figure 4 In contrast to the exemplary embodiment shown in FIG. 1 which lacks the slip ring 320 , a Figure 5 and Fig. 8A The design of the slip ring 320 is provided in a specific embodiment shown by way of non-limiting example in FIG. In a specific embodiment, the slip ring 320 can be configured to be generally annular. Thus, in a specific embodiment, the slip ring 320 can provide an optimal contact surface area for supporting the armature 220 and / or for selectively coupling axial forces and / or axial translations between the armature 220 and the locking plate 140 in one or both directions. By way of example and not limitation, such as for Figure 5 In the embodiment shown in , full 360° contact can be achieved between the slip ring 320 and the armature 220. Full 360° contact can be achieved between the slip ring 320 and each of the one or more transfer pins 340, either individually or in addition.

[0061] In certain embodiments, the slip ring 320 may be made of certain materials (eg, non-metallic materials) and have at least the advantage of not interfering with sensitive magnetic sensing devices (eg, lock detection sensor assembly 410 ) associated with the differential assembly 110 , as will be discussed further herein.

[0062] In certain embodiments, the slip ring 320 can provide radial support, restraint, and / or guidance to certain components that engage the slip ring 320. In certain embodiments, guiding a component can involve mechanically restraining the component to a concentric position about the axis of rotation of the differential assembly 110. As an example and not limitation, relative to the rotating components of the differential assembly, rotating stationary components such as armatures and stator housings need to be guided to remain concentrically positioned about the same axis as the rotating components. Guiding these components may require providing resistance to forces and moments that may cause the axes of these components to tilt and / or offset relative to the axis of rotation of interest (such as the axis of rotation of the differential assembly 110).

[0063] In certain embodiments, the slip ring 320 can be configured to radially align and / or guide the armature 220 relative to the axis of rotation of the differential assembly 110. By way of example and not limitation, such as Figure 1 and Figure 5 As shown in , the armature 220 can be partially or completely radially supported on or by the slip ring 320. In certain embodiments, the slip ring 320 can be configured to radially align and / or guide the stator 230 (such as the stator housing 232) relative to the rotation axis of the differential assembly 110. By way of example and not limitation, such as Figure 1 As shown in , the stator housing 232 may be partially or completely radially supported on or by the slip ring 320 .

[0064] Based on mechanics, it is understandable that engagement surfaces having larger areas and / or located at larger radii from the axis of rotation may be ideal for effective guidance of concentrically positioned components. However, recent applications such as electric vehicles have introduced more compact packaging requirements and higher torque density specifications, which can present significant design challenges.

[0065] In certain embodiments, specific features may be used in combination with the slip ring 320 to axially constrain relative movement of specific components engaged with the slip ring 320, and / or to more rigidly constrain specific components to move with the locking plate 140 and / or transfer pin 340 in a tightly coupled and axially corresponding manner.

[0066] In certain embodiments, the slip ring assembly 310 may also include one or more features for axially constraining an engagement component relative to the slip ring 320, wherein the engagement component may include, as non-limiting examples, the armature 220, the stator 230, and / or the transfer pin 340. By way of example and not limitation, such as Figure 5 As shown relative to the armature 220 in FIG. 1 , grooves and / or raised edges may be provided in the slip ring 320 to axially constrain the engagement member. Alternatively or in addition, external structures, features, and / or components may be used to axially constrain the engagement member relative to the slip ring 320. By way of example and not limitation, one or more of washers, snap rings, circlips, C-clips, and / or e-clips may be used to provide axial restraint. By way of example and not limitation, Figure 5 and Fig. 12C The use of a snap ring 238 to axially constrain the armature 220 in one direction is depicted. By way of example and not limitation, Figure 8C and Fig.12D The use of an e-clip 326 to axially constrain the transfer pin 340 relative to the slip ring 320 is depicted. By way of example and not limitation, Fig. 8A A groove 328 is shown disposed on the slip ring 320 , which in certain embodiments may be used to receive and / or capture the snap ring 238 .

[0067] In certain embodiments, a retaining ring 260 may be used to axially constrain the stator housing 232 in place. By way of example and not limitation, the retaining ring 260 may axially constrain the stator housing 232 relative to the differential housing 130. In certain embodiments, such as in Figure 8C As shown in the non-limiting example, the retaining ring 260 can be a multi-part retaining ring. In a particular embodiment, the retaining ring 260 can include a discontinuous retaining ring.

[0068] In particular embodiments, the differential housing 130 may be referred to as a differential case.

[0069] In certain embodiments, the slip ring 320 may include at least one axial groove or channel to allow the flow of a hydraulic fluid, such as oil. By way of example and not limitation, the channel may provide improved lubrication. In certain embodiments, such as Figure 8C , Fig. 12B and Fig. 12C As depicted by the oil flow channel 324 in , the axial groove or channel can help reduce the hydraulic damping generated when the slip ring assembly 310 is axially translated. In a specific embodiment, the axial groove or channel for lubrication purposes can be combined with a corresponding feature to facilitate reducing hydraulic damping. In a specific embodiment, one function or the other function or both functions can be achieved by different structures. In a specific embodiment, only a specific function of the lubrication function and / or the hydraulic damping reduction function may be required or provided. As an example and not limitation, by providing better hydraulic fluid flow to reduce hydraulic damping, the state change and / or actuation of the locking and unlocking of the differential assembly 110 can be allowed to be faster, such as based on the power on and / or power off of the electronic actuator assembly 210.

[0070] In certain embodiments, for each of the one or more transfer pins 340, the slip ring 320 may include a hole 342 having a hole diameter configured to receive the corresponding transfer pin 340. Fig. 8A , Figure 8C and Fig. 12B As shown in FIG. 3 , the slip ring 320 may include one or more slots 322. In certain embodiments, the one or more slots 322 may provide and / or improve access to the transfer pin 340. In certain embodiments, the slot width 323 of the slot 322 may be in a range between 1 and 10 times the hole diameter of the hole 342.

[0071] In some embodiments, it may be desirable and / or regulated to verify the locked or unlocked state of the differential assembly 110 by physical sensing. As an example and not limitation, it may be unsafe and / or inefficient to operate a vehicle with an actual differential locked state contrary to the user's expectations or information.

[0072] In certain embodiments, a lock detection sensor assembly 410 may be used to sense the differential lock state. Figure 1 , Figure 2 , Fig.10 and Fig. 12B As shown by way of non-limiting example, the lock detection sensor assembly 410 may include a lock detection sensor 420 and / or a sensor target 430. In certain embodiments, the lock detection sensor assembly 410 may be configured to detect an axial distance between the armature 220 and the stator 230.

[0073] In a particular embodiment, the lock detection sensor 420 (such as a Hall effect sensor) can be configured to operate based on detecting magnetic field strength and / or related quantities (such as magnetic field strength and / or magnetic flux). As an example and not a limitation, the lock detection sensor 420 can be configured to detect the magnitude and / or direction of these or other specific physical quantities. In a particular embodiment, the lock detection sensor 420 can be calibrated to associate the changing relative distance of the target (such as the axial distance of the sensor target 430) with the measured changing magnetic field strength and / or other physical quantity. In a particular embodiment, the lock detection sensor 420 may be sensitive to the influence and disturbance of other adjacent components on the surrounding magnetic field, whether desired or unintentional. As an example and not a limitation, unexpected changes in the measured magnetic field strength generated based on the distribution of rotating components around the lock detection sensor 420 may reduce the accuracy and / or precision of the lock detection sensor assembly 410 when detecting the axial distance between the armature 220 and the stator 230.

[0074] In particular embodiments, to allow lock detection sensor assembly 410 to detect an axial distance between armature 220 and stator 230 , one of lock detection sensor 420 and sensor target 430 may be coupled to armature 220 and the other of lock detection sensor 420 and sensor target 430 may be coupled to stator 230 .

[0075] As an example and not limitation, according to certain embodiments, the lock detection sensor 420 may be rigidly attached to the reference frame of the stator housing, such as via a sensor post 450. As an example and not limitation, according to certain embodiments, a sensor target 430 (such as a magnetic target) may be rigidly attached to the axially movable armature 220, such as via a sensor target bracket 435, to translate axially therewith.

[0076] In certain embodiments, such as based on the ideal complete axial coupling of the armature 220 and the locking plate 140 in both directions, the axial position of the armature 220 can be used as a substitute for the locked state or unlocked state and / or the relative axial position of the locking plate 140 relative to the locking gear 135. Such (effective) detection of the relative axial distance between the armature 220 and the stator 230, thereby determining the locked state or unlocked state and / or the axial position of the locking plate 140 relative to the locking gear 135, can also be achieved by other suitable means of detecting proximity and / or physical contact.

[0077] By way of example and not limitation, in ideal operation, as described above, when the stator 230 is de-energized, there may be no rightward force exerted on the armature 220 (at Figure 1 Therefore, in certain embodiments and according to Figure 1 In the reference frame in FIG. 1 , based on the return spring 150 pushing the locking plate 140 to the left, the locking plate 140 can be axially translated in the left direction, which in turn can apply force to the armature 220 via the transfer pin 340 and correspondingly cause the armature to be axially translated to the left. According to this non-limiting example, the corresponding increased distance between the sensor target 430 (attached to the armature 220) and the lock detection sensor 420 (attached to the stator 230) can be interpreted as the differential assembly 110 being in an unlocked state.

[0078] On the contrary, according to Figure 1 In the same specific embodiment in the same reference frame in FIG. 2 , when the stator 230 is energized, the magnetic attraction force exerted on the armature 220 can pull the armature 220 to the right, and the armature can be translated to the locking plate 140 through one or more of the slip ring 320 and the transfer pin 340, thereby placing the differential assembly 110 in a locked state. According to this non-limiting example, the corresponding reduced distance between the sensor target 430 (attached to the armature 220) and the lock detection sensor 420 (attached to the stator 230) can be interpreted as the differential assembly 110 being in a locked state.

[0079] As discussed previously herein, independent verification of a locked state or an unlocked state, such as that provided by the lock detection sensor assembly 410, can be important for safe and / or efficient operation of a vehicle. However, depending on the particular design and / or vehicle operating conditions, the respective axial positions of the armature 220 and the locking plate 140 may not completely correspond to each other, which may result in the lock detection sensing being inaccurate in determining or interpreting the locked state or the unlocked state of the differential assembly 110.

[0080] By way of example and not limitation, in certain embodiments and / or operating conditions, although the stator 230 is de-energized and thus the armature 220 is released to move away from the stator (at Figure 1 , but locking plate 140 may still accidentally and / or undesirably remain in the locked position.

[0081] In certain embodiments, such a situation where the armature 220 and the locking plate 140 axially move in a non-corresponding manner may be caused by a so-called "torque trap" situation. By way of example and not limitation, a "torque trap" may be generated based on the torque applied to maintain the locking plate 140 in engagement with the locking gear 135, gear meshing forces, and / or friction between the locking plate 140 and the surface it contacts, such as due to the torque and / or force exceeding the ability of the return spring 150 to separate the locking plate 140 from the locking gear 135. In such an undesirable and / or unexpected situation, for example, the lock detection sensor assembly 410 may erroneously interpret the axial position of the armature 220 as indicating that the differential is unlocked, while the locking plate 140 may actually continue to maintain the differential assembly 110 in a locked state, such as by continued engagement with the locking gear 135.

[0082] In certain embodiments, the armature 220 (and, by extension, components of the lock detection sensor assembly 410 that may be coupled to the armature 220, such as the sensor target 430) may tilt, rotate, deflect, translate, or otherwise move, either alone or in addition, due to vibrations, bumps, and other disturbances that occur during operation. Such position disturbances, vibrations, and / or disturbances of the armature 220 and / or coupled components of the lock detection sensor assembly 410 may cause the sensor to detect an interpretation of a locked state or unlocked state that is opposite to the actual locked state or unlocked state of the differential assembly 110. Deviations in the positioning capability of the armature 220 from its design intent may be referred to as runout, which may result in changes in the ability to accurately sense the locked position of the differential assembly 110.

[0083] Therefore, it is important to properly constrain the armature 220 so that it: (a) translates axially correctly in the locked and unlocked states and moves axially with the locking plate 140 in a closely corresponding manner (e.g., via the slip ring 320, transfer pin 340 and / or other features used alone or in addition), and (b) is guided to remain concentric with the axis of rotation of the differential assembly 110 and / or resist tilting, rotation, misalignment and other movement due to disturbances during operation.

[0084] As discussed previously herein, the specific design features disclosed herein can be used to provide one or more of the following: (i) relative rotational movement (slipping) between the armature 220 and the slip ring 320 to allow the armature 220 to remain rotationally stationary relative to the rotating components of the differential assembly 110; (ii) transmit axial forces and / or axial translations between the armature 220 and the slip ring 320; and (iii) more rigidly constrain the armature 220 to move axially together with the slip ring 320, the transfer pin 340 and / or the locking plate 140 in a closely corresponding manner.

[0085] In certain embodiments, such as Figure 1 As shown in , the armature 220 can be radially constrained and / or guided by the surface of the slip ring 320 at the inner diameter of the armature 220. In some embodiments, the corresponding engagement surfaces or contact surfaces of the armature 220 and the slip ring 320 may not be in contact along one or both of their entire axial lengths. In certain embodiments, the armature 220 can be supported, constrained and / or guided in multiple dimensions. By way of example and not limitation, such as Figure 5 As shown in FIG. 1 , the armature 220 may engage a generally flat section of the slip ring 320 at its inner diameter and / or be axially constrained between a raised edge or lip section of the slip ring 320 and the snap ring 238. In certain embodiments, such as Figure 1 As shown in , a longer section or the entire inner diameter surface of the armature 220 (ie, along the entire axial length) may be supported and / or guided at the surface that engages or contacts the slip ring 320 .

[0086] The side-by-side comparison provided by way of non-limiting example in FIGS. 6 and 7 , respectively, may provide a visual comparison of relevant design choices and configurations of particular embodiments for supporting the armature 220 and / or for transmitting axial motion between the armature 220 and the locking plate 140 .

[0087] In a particular embodiment, the transfer pin 340 can be configured to be press-fitted into the locking plate 140. Separately or additionally, in a particular embodiment, the transfer pin 340 can be configured to be press-fitted into the slip ring 320. One or both of the above features can constrain the axial travel of the armature 220, separately or additionally, to follow the axial travel of the locking plate 140 and / or to be almost equivalent to the axial travel of the locking plate in other ways, that is, to make the armature axial movement and the locking plate axial movement have a higher correspondence. In a particular embodiment, there can be one or more separate or additional features, such as a mechanical coupling feature between the transfer pin 340 and the slip ring 320. As an example and not a limitation, the additional features, devices and / or methods may include a press fit, a snap ring, a keyway and / or a weld. In some embodiments, there may be a mechanical connection between the transfer pin 340 and the locking plate 140, for example, by a press fit, a snap ring, a keyway and / or a weld.

[0088] In some embodiments, additional components, such as snap rings, may be used to further axially constrain the armature. Figure 1 and Figure 5 In the example that can be seen in , the snap ring 238 is depicted as being located at the lower left corner of the armature 220 (in the reference frame of these figures) to constrain the armature 220 from further translation to the left relative to the slip ring 320.

[0089] As disclosed, certain embodiments, including the use of slip rings 320 in the context of an electronically locking differential assembly 110, can provide performance advantages during operation under designed conditions as well as during unexpected behavior under undesigned conditions. Use of slip rings 320 in this context can, alone or in addition, provide benefits related to manufacturing, assembly, maintenance, repair, maintenance, and / or replaceability.

[0090] In certain embodiments, as discussed previously herein, the stator 230, including the stator housing 232 (and the stator coils 234 therein), can be held rotationally stationary relative to certain rotating components (such as the differential housing) of the differential assembly 110. Alternatively or additionally, for several embodiments disclosed herein, the armature 220 can be held rotationally stationary relative to certain rotating components of the differential assembly 110.

[0091] In a particular embodiment, keeping a particular component rotationally stationary relative to other rotating components of the differential assembly 110 can be achieved by rigidly connecting these components of interest to one or more other rotationally stationary elements (such as external structural elements). As an example and not limitation, the rotationally stationary external structural elements may include a wheel axle housing, a cover, and / or an outer shell. In a particular embodiment, the structural element used to constrain a given component of the differential assembly 110 to be rotationally stationary may be referred to as an anti-rotation element in this article. In a particular embodiment, the anti-rotation function may be provided by a component developed specifically for this purpose (such as, based on design requirements and packaging constraints). As an example and not limitation, the anti-rotation function may be provided by an anti-rotation tab and / or an anti-rotation bracket.

[0092] Figure 8B and Fig. 9 A schematic front perspective view of an electronic locking differential assembly according to a particular embodiment is shown. By way of example and not limitation, Figure 8B and Fig. 9 The following embodiments are depicted: (i) an anti-rotation bracket 280 for rotationally constraining the stator housing 232 to be rotationally stationary relative to a rotating component, such as by engaging an external support in the axle housing 510, and (ii) an anti-rotation tab 270 for rotationally locking the armature 220 to the stator housing 232, thereby constraining the armature 220 to be rotationally stationary based on the stator housing 232 being rotationally stationary due to the anti-rotation tab 270. It should be understood that while specific methods and devices for providing the anti-rotation function are illustrated, the present disclosure fully contemplates any suitable devices and methods for providing the anti-rotation function and / or combinations thereof.

[0093] In certain embodiments, clocking of components may refer to positioning components (e.g., concentrically arranged components) circumferentially relative to each other and / or relative to an external circumferential reference. As an example and not limitation, in certain embodiments, lock detection sensor 420 may be clocked relative to stator housing 232 such that lock detection sensor 420 is positioned at a circumferentially specific location relative to sensor target 430, wherein the lock detection sensor and sensor target may be co-located circumferentially (e.g., see Figure 1 and Figure 2 In certain embodiments, the sensor target 430 may be positioned annularly based on the armature 220 so that the sensor target 430 is properly positioned circumferentially relative to the lock detection sensor 420 (eg, Figure 1 and Figure 2 ).

[0094] In certain embodiments, the tabs or coupling tabs may be used alone or in addition to annularly position the armature 220 relative to the stator housing 232. By way of example and not limitation, Figure 8B and Fig. 9 The anti-rotation tabs 270 depicted in FIG. 2 can be used to rotationally lock the armature 220 to the stator housing 232 while allowing relative axial movement therebetween.

[0095] In certain embodiments, design aspects of the metal tabs and / or asymmetric circumferential distribution of such tabs may interfere with sensitive magnetic sensing devices associated with differential assembly 110, such as lock detection sensor assembly 410. Other details and aspects related to lock detection sensors are further discussed herein.

[0096] In certain embodiments, a combination of functions, such as anti-rotation, annular positioning, and / or routing, as non-limiting examples, may be performed by one or more structures (which may be multi-functional structures). In certain embodiments, the multi-functional structures may address specific design and / or packaging constraints of the differential assembly 110.

[0097] By way of example and not limitation, such as Fig.10 , Fig.11 , Fig. 12A and / or Fig. 12B As shown in , annular positioning and / or rotational locking of the armature 220 relative to the stator 230 can be provided by the anti-rotation assembly 290. In a particular embodiment, the anti-rotation assembly 290 can be disposed in the vicinity of the lock detection sensor assembly 410. Separately or additionally, in a particular embodiment, the anti-rotation assembly 290 can be disposed in a suitable and / or symmetrical position, such as a magnetically symmetrical position relative to the lock detection sensor assembly 410.

[0098] As in Fig.10 , Fig.11 , Fig. 12A and / or Fig. 12B As shown by way of non-limiting example in FIG. 1 , in certain embodiments, the anti-rotation assembly 290 can include a sensor post 450 rigidly connected to the stator housing 232 and the lock detection sensor 420. In certain embodiments, the sensor target 430 can be rigidly connected to the armature 220 via a sensor target bracket 435.

[0099] In certain embodiments, annular positioning and / or rotational locking between the lock detection sensor and the sensor target may be achieved by anti-rotation assembly 290. By way of example and not limitation, such as Fig.10 and Fig.11As shown in , annular positioning and / or rotational locking can be achieved by positioning or capturing a member (such as a sensor target bracket 435) coupled to the armature 220 between rigid extension structural elements (such as forks 460). The extension structural members can be provided on one or both sides of a corresponding member (such as a sensor post 450) coupled to the stator housing 232. Thus, in a particular embodiment, the anti-rotation assembly 290 can constrain relative rotational movement between the fork 460 and the sensor target bracket 435 sandwiched therebetween. Based on their respective rigid connections to the sensor post 450 and the sensor target bracket 435, annular positioning and / or rotational locking can be achieved between the stator housing 232 and the armature 220 through this arrangement.

[0100] By way of example and not limitation, such as FIG. 12A to FIG. 12C As shown in , an extended structural element, such as a fork 460 , may be disposed on a sensor target bracket 435 coupled to the armature 220 , such that a sensor post 450 coupled to the stator housing 232 may be captured therebetween.

[0101] In certain embodiments, the anti-rotation assembly 290 may include a connection member, such as a sensor post 450, that couples the lock detection sensor 420 to the stator housing 232. In certain embodiments, separately or additionally, a connection member, such as a sensor target bracket 435, may be provided for coupling the sensor target 430 to the armature 220. In certain embodiments, either or both of the connection members, such as the sensor post 450 and / or the sensor target bracket 435, may be configured to constrain the armature 220 in a fixed rotational position relative to the stator 230. As an example and not limitation, either or both of the connection members may include one or more extension structures, such as a fork 460, to constrain the armature 220 in a fixed rotational position relative to the stator 230.

[0102] In certain embodiments, such as Fig. 12A As shown by way of non-limiting example in the figure, a multifunctional structure such as an integral housing 292 can be configured to provide multiple functions. As an example and not limitation, the integral housing 292 can provide a housing for the lock detection sensor 420, and / or protect and guide the electrical leads 240 of the stator 230 and / or the electrical leads 440 of the lock detection sensor assembly 410. In a particular embodiment, multiple groups of electrical leads such as those described above can be combined into a single cable 295, which can optionally terminate in a single electrical connector for connection to a vehicle wiring harness. Separately or additionally, the integral housing 292 can include, cover, or be coupled to a sensor post 450.

[0103] Some implementations of features may adversely affect the detection capabilities of the lock detection sensor assembly 410, such as by interfering with the magnetic field and / or magnetic flux distribution around the lock detection sensor assembly 410. These features (which may include but are not limited to the slip ring 320, one or more transfer pins 340, the anti-rotation assembly 290, and / or the tab 270) may adversely affect the detection capabilities of the lock detection sensor assembly 410 based on their respective relative positions and / or the distribution or relative positions of magnetic asymmetry.

[0104] In a particular embodiment, the detection of the axial distance between the stator 230 and the armature 220 by the lock detection sensor assembly 410 can be implemented based on the detection of the magnetic field strength. As an example and not a limitation, the slip ring 320 can be configured to be symmetrical about the rotation axis passing through the differential assembly 110 and the longitudinal plane of the lock detection sensor assembly 410, such as magnetic symmetry, to facilitate improving the accuracy of the lock detection. As an example and not a limitation, the distribution of the transfer pin 340 can be configured to be symmetrical about the rotation axis passing through the differential assembly 110 and the longitudinal plane of the lock detection sensor assembly 410, such as magnetic symmetry, to facilitate improving the accuracy of the lock detection. As an example and not a limitation, the symmetry of the slip ring 320 can refer to the magnetic field symmetry based on the slip ring 320, and / or the magnetic field disturbance caused by the slip ring 320. In a particular embodiment, the symmetry of the slip ring 320 can be implemented based on the rotation of the slip ring 320 around the rotation axis of the differential assembly 110.

[0105] Based on their relative positions relative to the lock detection sensor assembly 410, appropriate selection of materials, designs, geometries, relative positions and / or relative distributions of the slip ring 320, transfer pin 340, anti-rotation assembly 290 and / or tabs 270 (but not limited to such) can significantly reduce or eliminate such undesirable interfering effects on the sensing capabilities of the lock detection sensor, for example by reducing or eliminating magnetic variations, interferences and / or losses.

[0106] Miscellaneous

[0107] The foregoing description of the embodiments is provided for the purpose of illustration and description. The description is not intended to be exhaustive or to limit the present disclosure. Although several embodiments of the apparatus, system and method have been described in detail, including the best mode, those familiar with the field to which the present disclosure belongs will recognize multiple alternative designs and embodiments for practicing the teachings. The individual elements or features of a particular embodiment are generally not limited to the particular embodiment, but are interchangeable where applicable and can be used in the selected embodiment, even if the embodiments are not specifically shown or described. For example, each feature described in an example of an embodiment can be combined with one or more other required features from other embodiments to form other embodiments that are not described in words or with reference to the drawings. It should also be understood that changes and modifications can be made by those of ordinary skill in the art, and these changes and modifications are within the scope of the present disclosure, the specification and / or the appended claims. These variations are fully contemplated herein, and these variations should not be considered as departing from the present disclosure, and all these modifications are intended to be included within the scope of the present disclosure.

[0108] The terms used in the claims should be interpreted as having the broadest reasonable interpretation consistent with the preceding description. For example, the article "a" or "the" used when introducing an element should not be interpreted as excluding the case of multiple elements. Similarly, the recitation of "or" should be interpreted as inclusive, so that the recitation of "A or B" does not exclude the case of "A and B", unless it is clear from the context or the preceding description that only one of A and B is present. In addition, whether A, B, and C are related in category or otherwise, the recitation of "at least one of A, B, and C" should be interpreted as one or more elements in a group of elements consisting of A, B, and C, and should not be interpreted as requiring at least one element of each of the listed elements A, B, and C. In addition, the recitation of "A, B, and / or C" or "at least one of A, B, or C" should be interpreted as including any single entity of the listed elements (e.g., A), any subset of the listed elements (e.g., A and B), or the entire list of elements A, B, and C.

[0109] The numerical ranges listed in this application should be interpreted as including the endpoints of the stated ranges. Certain axes (such as one or more rotational axes, transverse axes and / or longitudinal axes) that may be omitted in some of the drawings herein should be interpreted as being present in each drawing or situation mentioned.

Claims

1. A lockable differential assembly comprising: a locking plate rotatable about a rotational axis, wherein the differential assembly is configured to be in a locked state or an unlocked state based on selective axial engagement of the locking plate relative to the locking gear; an actuator assembly including a stator and an armature, the actuator assembly being configured to switch between an energized state and a de-energized state; and A slip ring assembly configured to translate axially corresponding to the locked state or the unlocked state of the differential assembly, the slip ring assembly comprising: a slip ring engaged with the armature at a sliding surface configured to allow relative rotation between the slip ring and the armature; and one or more pins to rotationally lock the slip ring to the locking plate, wherein the slip ring assembly is configured to transmit an axial locking force from the actuator assembly to the locking plate when the actuator assembly is energized, and Wherein, the slip ring assembly is configured to transmit an axial reset force from the locking plate to the actuator assembly when the actuator assembly is de-energized. 2 . The differential assembly of claim 1 , further comprising a lock detection sensor assembly, the lock detection sensor assembly comprising a sensor and a target, the lock detection sensor assembly configured to detect an axial distance between the stator and the armature.

3. The differential assembly according to claim 2, wherein: One of the sensor and the target is coupled to the armature, and the other of the sensor and the target is coupled to the stator.

4. The differential assembly according to claim 2, further comprising an anti-rotation assembly, the anti-rotation assembly comprising: a first connecting member coupling the sensor of the lock detection sensor assembly to a stator housing of the actuator assembly; as well as a second connecting member coupling the target of the lock detection sensor assembly to the armature, Wherein, the first connection member or the second connection member includes one or more extension structures configured to constrain the armature in a fixed rotational position relative to the stator.

5. The differential assembly according to claim 2, wherein: The lock detection sensor assembly detects the axial distance between the stator and the armature based on detecting the intensity of the magnetic field.

6. The differential assembly according to claim 1, wherein: The stator includes a stator coil, wherein energizing the actuator assembly includes flowing current through the stator coil to generate a magnetic field, and wherein the armature experiences a magnetic force toward the stator coil based on the magnetic field generated when the actuator assembly is energized.

7. The differential assembly according to claim 6, wherein: The slip ring is configured to focus the magnetic field generated by the actuator assembly when in the energized state through an air gap between the armature and the stator, so as to facilitate improving the efficiency of the actuator assembly in actuating the locking state of the differential assembly.

8. The differential assembly according to claim 1, wherein: The slip ring comprises at least one axial groove to allow the flow of hydraulic fluid for lubrication.

9. The differential assembly according to claim 1, wherein: The slip ring includes at least one axial groove to help reduce the hydraulic damping generated when the slip ring assembly translates along the axial direction.

10. The differential assembly of claim 1, wherein: For each of the one or more pins, the slip ring comprises: a hole having a hole diameter and configured to receive a corresponding pin; and a slot configured to facilitate entry of a corresponding pin, Therein, a slot width of the slot has a value between the hole diameter and ten times the hole diameter.

11. The differential assembly according to claim 1, wherein: The slip ring is configured to radially align the armature with respect to the rotational axis.

12. The differential assembly of claim 1, wherein: The slip ring is configured to radially align the stator with respect to the rotation axis.

13. The differential assembly of claim 1, wherein: The slip ring assembly also includes one or more features for axially constraining the armature relative to the slip ring.

14. The differential assembly of claim 1, wherein: The slip ring assembly also includes one or more features for axially constraining the slip ring relative to one or more of the pins.

15. The differential assembly according to claim 13 or 14, wherein: The one or more features may include a groove or a raised edge provided in the slip ring or one or more of the pins.

16. The differential assembly according to claim 13 or 14, wherein: The one or more features include a washer, a snap ring, or an e-clip.

17. The differential assembly of claim 1, wherein: One or more of the plurality of pins are press fit into the locking plate.

18. An electronically lockable differential assembly capable of lock detection, the differential assembly comprising: Differential housing; a locking gear rotatably disposed in the differential housing; a locking plate rotatable about an axis of rotation, wherein the differential assembly is configured to be in a locked state or an unlocked state based on selective axial engagement of the locking plate relative to the locking gear; a biasing member configured to axially bias the locking gear away from the locking plate; an actuator assembly including a stator and an armature, the actuator assembly being configured to switch between an energized state and a de-energized state; a lock detection sensor assembly including a sensor and a target, the lock detection sensor assembly being configured to detect an axial distance between the stator and the armature; and A slip ring assembly configured to translate axially corresponding to the locked state or the unlocked state of the differential assembly, and comprising: a slip ring engaged with the armature at a sliding surface, the slip ring being configured to allow relative rotation between the slip ring and the armature; and one or more pins to rotationally lock the slip ring to the locking plate, wherein the slip ring assembly is configured to transmit an axial locking force from the actuator assembly to the locking plate when the actuator assembly is energized, and Wherein, the slip ring assembly is configured to transmit an axial reset force from the locking plate to the actuator assembly when the actuator assembly is de-energized.

19. The differential assembly of claim 18, wherein: The slip ring includes at least one axial groove to allow the flow of hydraulic fluid and help reduce hydraulic damping generated when the slip ring assembly translates axially.

20. A method of assembling a lockable differential assembly, the method comprising: providing a locking gear and a locking plate within the differential housing, the locking gear and the locking plate being selectively engageable by relative axial translation, the locking gear and the locking plate being axially biased apart by a biasing member and being rotatable about a rotational axis; The locking plate is rotationally locked to the slip ring via one or more pins, the slip ring assembly comprising the slip ring and the one or more pins; providing an actuator assembly, the actuator assembly comprising a stator and an armature, the slip ring being axially locked with the armature, and a sliding interface between the slip ring and the armature being configured to allow relative rotation between the slip ring and the armature, wherein the armature is configured to translate axially toward the stator upon energizing the actuator assembly; and providing a lock detection sensor assembly including at least one sensor component coupled to each of the armature and the stator, respectively, and configured to detect an axial distance between the stator and the armature, wherein the slip ring assembly is configured to transmit an axial locking force from the actuator assembly to the locking plate when the actuator assembly is energized, and Wherein, the slip ring assembly is configured to transmit an axial reset force from the locking plate to the actuator assembly when the actuator assembly is de-energized.

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