Locking type differential mechanism

Abstract

A differential system is provided that includes a housing defining an interior cavity. The housing may have an aperture in communication with the interior cavity. A pair of planetary gears may be positioned within the internal cavity and rotatably coupled to the housing. A first half axle gear and a second half axle gear positioned within the interior cavity are in meshing engagement with the planetary gear and are rotatably coupled to the housing. The moving member is configured to rotate with the housing and move between an engaged position and a disengaged position. The housing is drivingly coupled to the first side gear when the moving member is in the engaged position. The electromagnetic actuation coil is positioned not to rotate with the housing and is configured to generate a magnetic field to move the moving member from the disengaged position to the engaged position.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 380,050, filed on October 18, 2022, the entire content of which is hereby incorporated by reference in its entirety and for all purposes. Technical Field

[0003] This application relates to a locking differential, and more particularly, to a locking differential with improved efficiency, which has general applicability in many products and industries including vehicles, robots, and manufacturing. Background Art

[0004] In the case of a vehicle, a locking differential ("lock") can lock the vehicle's axles together to provide 100% of the available torque to the drive wheels. Thus, when traction is needed, the axles can be mechanically locked together, forcing the wheels to rotate at the same speed. However, during turning, the locking differential needs to operate like an open differential to allow the wheels to rotate at different speeds. Summary of the Invention

[0005] In some aspects, the techniques described herein relate to a differential system, comprising: a housing that defines an internal cavity; a pair of planetary gears positioned within the internal cavity and rotatably coupled to the housing; a first side gear and a second side gear positioned within the internal cavity, meshingly engaged with the planetary gears and rotatably coupled to the housing; a moving member configured to rotate with the housing and move between an engaged position and a disengaged position, wherein when the moving member is in the engaged position, the housing is drivingly coupled to the first side gear; and an electromagnetic actuator coil positioned to not rotate with the housing and configured to generate a magnetic field to move the moving member from the disengaged position to the engaged position.

[0006] In some aspects, the techniques described herein relate to a differential system, wherein the moving member further comprises: a substrate; a first wall; and a second wall.

[0007] In some aspects, the techniques described herein relate to a differential system, wherein the first wall is longer than the second wall.

[0008] In some aspects, the techniques described herein relate to a differential system, wherein the electromagnetic actuator coil does not contact the moving member.

[0009] In some aspects, the techniques described herein relate to a differential system, wherein the electromagnetic actuator coil further does not contact the housing.

[0010] In some aspects, the techniques described herein relate to a differential system in which a moving member is spaced apart from an electromagnetic actuator coil by a gap when the moving member is in an engaged position and a disengaged position.

[0011] In some aspects, the techniques described herein relate to a differential system in which, when the moving member is in the engaged position, the gap is between 0.1 mm and 2 mm.

[0012] In some aspects, the techniques described herein relate to a differential system in which, when the moving member is in the disengaged position, the gap is between 3 mm and 7.5 mm.

[0013] In some aspects, the techniques described herein relate to a locking differential system, comprising: a plurality of rotating components, including: a housing that defines an internal cavity; a first half shaft gear and a second half shaft gear, the first half shaft gear and the second half shaft gear being positioned within the internal cavity; and a moving member configured to move between a differential lock position and a differential unlock position; a plurality of non-rotating components, including: an electromagnetic actuator component that does not contact the plurality of rotating components; wherein the electromagnetic actuator component interacts with the moving member to move the moving member between the differential lock position and the differential unlock position; wherein, when the moving member is in the differential lock position, the first half shaft gear is locked relative to the second half shaft gear.

[0014] In some aspects, the techniques described herein relate to a locking differential system, wherein the electromagnetic actuator component includes a first actuator surface, and the moving member includes a first moving member surface that faces the first actuator surface; and wherein there is a gap between the first moving member surface and the first actuator surface.

[0015] In some aspects, the techniques described herein relate to a locking differential system, wherein, in the differential unlock position, the gap between the electromagnetic actuator component and the moving member is between 6 mm and 4 mm; and wherein, in the differential lock position, the gap between the electromagnetic actuator component and the moving member is between 2 mm and 0.1 mm.

[0016] In some aspects, the techniques described herein relate to a locking differential system, wherein the first half shaft gear is connected to a first drive shaft, and the second half shaft gear is connected to a second drive shaft.

[0017] In some aspects, the techniques described herein relate to a locking differential system, wherein the plurality of rotating components further includes: a cam ring connected to the moving member; wherein, when the moving member is in the differential lock position, the cam ring directly engages the first half shaft gear.

[0018] In some aspects, the techniques described herein relate to a locking differential system in which a moving member is made of ferromagnetic metal.

[0019] In some aspects, the techniques described herein relate to a locking differential system, comprising: a housing that defines an internal cavity and has a rotational axis; a first gear and a second gear positioned within the internal cavity and rotatable about the rotational axis; a moving member configured to rotate with the housing and move in a direction parallel to the rotational axis; and an attracting element configured to move the moving member; wherein the attracting element does not contact the moving member.

[0020] In some aspects, the techniques described herein relate to a locking differential system in which, in a differential locked state and a differential unlocked state, the attracting element does not contact the housing, the first gear, or the second gear.

[0021] In some aspects, the techniques described herein relate to a locking differential system in which the moving member includes a first wall configured to interact with the attracting element.

[0022] In some aspects, the techniques described herein relate to a locking differential system in which the moving member further includes a second wall configured to interact with the attracting element.

[0023] In some aspects, the techniques described herein relate to a locking differential system in which the first wall is longer than the second wall.

[0024] In some aspects, the techniques described herein relate to a locking differential system in which, when the differential is in a locked state, the first wall and the second wall at least partially surround the attracting element. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention is described with reference to the accompanying drawings, in which like reference numerals represent like elements and in which:

[0026] Figure 1 is a representation of a differential with an in-differential drive unit according to aspects of the present disclosure.

[0027] Figure 2 shows Figure 1 an alternative view of the in-differential drive unit of

[0028] Figure 3 shows Figure 1 an alternative view of the in-differential drive unit of

[0029] Figure 4AShows a more detailed view of the drive unit within the differential, particularly a part of the rotational locking assembly of the drive unit within the differential.

[0030] Figure 4B Shows Figure 4A an alternative view of the drive unit within the differential.

[0031] Figure 5 Shows a view of the drive unit within the differential housing in an unlocked state.

[0032] Figure 6A Shows an embodiment of the drive unit within the differential in a locked state.

[0033] Figure 6B Shows an alternative embodiment of the drive unit within the differential in a locked state.

[0034] Figure 7A is a diagram of the electromagnetic actuator coil.

[0035] Figure 7B is Figure 7A an alternative view of the electromagnetic actuator coil, showing the integrated connector.

[0036] Figure 8 is a diagram of the electromagnetic actuator coil.

[0037] Figure 8A Shows a part of the electromagnetic actuator coil.

[0038] Figure 8B Shows a part of the electromagnetic actuator coil, particularly the sensor body and the PWM controller housing.

[0039] Figure 8C Shows a part of the electromagnetic actuator coil, particularly the integrated connector.

[0040] Figure 9A Shows the solenoid coil housing of the electromagnetic actuator coil.

[0041] Figure 9B Shows the solenoid coil housing and the lugs.

[0042] Figure 10 Shows the solenoid coil of the electromagnetic actuator coil.

[0043] Figure 11A Shows the solenoid connector part after winding.

[0044] Figure 11B Shows the solenoid connector part after IDC pin installation.

[0045] Figure 11CShows the solenoid connector portion after the winding posts and excess wire have been trimmed.

[0046] Figure 12A Shows an exploded view of the solenoid coil and the solenoid coil housing.

[0047] Figure 12B Shows the same components in an assembled state as Figure 12A the same.

[0048] Figure 13A Shows Figure 12B an alternative view of the solenoid coil and the solenoid coil housing in

[0049] Figure 13B Shows the hot melt posts in Figure 13A after undergoing a hot melt operation.

[0050] Figure 14A Shows the components of the overmolded assembly.

[0051] Figure 14B Shows the overmolded assembly with overmolding material.

[0052] Figure 15A Shows the main PCB and the sensor assembly.

[0053] Figure 15B Shows Figure 15A the main PCB and the sensor assembly of

[0054] Figure 15C placed in the electromagnetic actuator coil as shown by the arrow after assembly.

[0055] Figure 16A Shows a detailed view of a part of the in-differential drive unit in an unlocked state.

[0056] Figure 16B Shows a detailed view of a part of the in-differential drive unit in a locked state. DETAILED DESCRIPTION

[0057] Generally, one or more aspects of the present disclosure relate to a locking differential and a locking mechanism for a differential. The locking differential disclosed herein has general applicability in many products and industries including vehicles, robots, manufacturing, aerospace, and industry. For ease of description, the locking differential will be described in the context of a vehicle (more specifically, in the context of an electric vehicle). However, the application of the locking differential disclosed herein is not limited to vehicles and has applicability in many industries.

[0058] Traditional methods of locking differentials mount a stationary actuator coil to a rotating differential housing, resulting in parasitic drag. This increase in parasitic drag causes a decrease in differential efficiency. In electric vehicles where range is critical, inefficiencies such as these are exacerbated.

[0059] To address some of the deficiencies associated with traditional locking differentials, the present disclosure describes a locking differential and components thereof that have less parasitic drag than traditional locking differentials.

[0060] Figure 1 is a representation of a differential 100 in accordance with aspects of the present application. In some embodiments, differential 100 includes a differential housing 102 that defines an internal cavity. In some embodiments, within differential housing 102, differential 100 also includes a ring gear 104 and an in-differential drive unit 200. In some embodiments, differential housing 102 is fixed to an associated vehicle. In some embodiments, within differential housing 102, both the ring gear 104 and the in-differential drive unit housing 202 of the in-differential drive unit 200 rotate. In some embodiments, ring gear 104 and in-differential drive unit 200 may be mechanically connected either indirectly or directly. In some embodiments, in-differential drive unit 200 is mechanically connected either directly or indirectly to an axle to drive the wheels of an associated vehicle.

[0061] Figure 2 shows an alternative view of in-differential drive unit 200. In some embodiments, in-differential drive unit 200 includes an in-differential drive unit housing 202. In some embodiments, within in-differential drive unit housing 202, in-differential drive unit 200 includes at least one planetary gear 204, a non-locking side gear 206, and a locking side gear 208. In the illustrated embodiment, in-differential drive unit housing 202 includes 2 planetary gears 204, however, for clarity, Figure 2 only one is shown. Planetary gears 204 rotate together with a cross shaft 210. Planetary gears 204 may be mechanically connected or interact with non-locking side gear 206 and locking side gear 208 to form a mechanical connection between non-locking side gear 206 and locking side gear 208. Non-locking side gear 206 may be connected to a first axle associated with a first side of the vehicle. Locking side gear 208 may be connected to a second axle associated with a second side of the vehicle.

[0062] In some embodiments, the in-differential drive unit 200 further includes a rotational locking assembly 300. In some embodiments, the rotational locking assembly 300 includes various components associated with a locking differential. When actuated, the rotational locking assembly 300 locks the position of the locked side gear 208 within the in-differential drive unit housing 202. When the locked side gear 208 is in a fixed position relative to the in-differential drive unit housing 202, the non-locked side gear 206 is also in a fixed position relative to the in-differential drive unit housing 202, and thus the first shaft associated with the first side of the vehicle is locked relative to the second shaft associated with the second side of the vehicle.

[0063] In some embodiments, the rotational locking assembly 300 includes one or more actuating pins 302. In some embodiments, the actuating pins 302 may be held in place by an actuating pin retaining plate 304. In some embodiments, the actuating pins 302 and / or the actuating plate 304 may be directly or indirectly mechanically connected to a cam plate 306 such that the actuating pins 302 and / or the actuating pin retaining plate 304 can push or pull on the cam plate 306 to actuate the rotational locking assembly 300. In some embodiments, the cam plate 306 is mechanically connected to a cam ring 308 such that when the rotational locking assembly 300 is actuated, the cam plate 306 can push or pull on the cam ring 308. The actuating pins 302 and / or the actuating plate 304 may be directly or indirectly mechanically connected to the cam ring 308.

[0064] In some embodiments, the rotational locking assembly 300 includes a return spring 310. In some embodiments, the return spring 310 biases the differential 100 to a non-actuated or unlocked state. The return spring 310 may be directly or indirectly mechanically connected to the cam ring 308 such that the return spring 310 pushes or pulls on the cam ring 308 to bias it towards the unlocked or non-actuated state. When the rotational locking assembly 300 is in the actuated state, the cam ring 308 engages the locked side gear 208. When the locked side gear 208 engages the cam ring 308, their positions are fixed relative to each other, and thus the positions of both the cam ring 308 and the locked side gear 208 relative to the in-differential drive unit housing 202 are fixed.

[0065] Figure 3Shows an alternative view of the drive unit 200 within the differential. As described above, the drive unit 200 within the differential includes a rotational locking assembly 300. In some embodiments, the rotational locking assembly 300 includes at least one actuating pin 302, and the at least one actuating pin 302 is connected to an actuating pin retaining plate 304. In some embodiments, the actuating pin 302 includes an end portion 312. In some embodiments, the end portion 312 may include a connection feature 314. In some embodiments, the connection feature 314 is configured to engage the actuating pin retaining plate 304. For example, in some embodiments, the connection feature 314 may be a notch engaged by the retaining plate 304. The connection feature 314 may be a recessed feature, a protruding feature, or any suitable feature. The actuating pin retaining plate 304 may capture, hold, lock, or connect to the actuating pin 302 in any suitable manner. The actuating pin retaining plate 304 may be made of a single piece. In some embodiments, the actuating pin retaining plate 304 is configured to capture multiple actuating pins 302 simultaneously. In some embodiments, the actuating pin retaining plate 304 includes an engagement feature 316. In some embodiments, the engagement feature 316 is configured to engage the actuating pin 302, particularly configured to engage the connection feature 314 on the end portion 312 of the actuating pin 302.

[0066] Figure 4A Shows a more detailed view of the drive unit 200 within the differential, particularly a portion of the rotational locking assembly 300 of the drive unit 200 within the differential. In some embodiments, when the rotational locking assembly 300 is actuated (placed in the locked state), the cam plate 306 pushes against the cam ring 308. In some embodiments, the cam plate 306 pushes the cam ring 308 towards the locking side gear 208. When the cam ring 308 moves the locking side gear 208, the return spring 310 is compressed. In the actuated position, the cam ring 308 engages the locking side gear 208. In some embodiments, the cam ring 308 includes a cam plate locking feature 318, and the cam plate locking feature 318 engages with the side gear locking feature 212. In some embodiments, the cam plate locking feature 318 and / or the side gear locking feature 212 are configured as locking face splines.

[0067] Figure 4B Shows Figure 4A An alternative view of the drive unit 200 within the differential. In some embodiments, the cam ring 308 includes a torque transfer pawl 320. In some embodiments, when the cam ring 308 engages the locking side gear 208 in the actuated state, there is a force on the cam ring 308. The torque transfer pawl 320 allows the transfer of force between the cam ring 308 and the differential housing 202. In some embodiments, the torque transfer pawl 320 allows the transfer of force regardless of the direction of rotation.

[0068] Figure 5 Shows a view of the in-differential drive unit 200 within the differential housing 102 in an unlocked state. In some embodiments, the in-differential drive unit 200 includes a rotational locking assembly 300 and a non-rotational locking mechanism 400. In some embodiments, the rotational locking assembly 300 includes the plurality of components previously discussed above and may also include an attracting moving plate 322, which may also be referred to as a movable member or a moving member. The attracting moving plate may be made of a ferromagnetic metal such as iron, cobalt, steel, nickel, manganese, or other materials. In some embodiments, the attracting moving plate 322 is mechanically connected to the actuating pin 302, as Figure 2 shown. When actuated, the attracting moving plate 322 is pulled towards the electromagnetic actuating coil 402 of the non-rotational locking mechanism 400. The electromagnetic actuating coil 402 (which may also be referred to as an attracting element) is fixed relative to the differential housing 102 and does not rotate during operation. When not actuated, the attracting moving plate 322 does not contact the electromagnetic actuating coil 402 to eliminate potential resistance.

[0069] In some embodiments, in the unlocked state, there is a gap between the electromagnetic actuating coil 402 and the attracting moving plate 322. In some embodiments, there is also a gap between the cam ring 308 and the locking halfshaft gear 208, and more specifically, there is a gap between the locking halfshaft gear locking feature 212 and the cam plate locking feature 318. In some embodiments, in the unlocked state, the return spring 310 is in a stretched state.

[0070] Figure 6AA view of the in-differential drive unit 200 in a locked state is shown. In the locked state, the attracting moving plate 322 is pulled towards the electromagnetic actuator coil 402. For example, in some embodiments, the attracting moving plate 322 moves towards the electromagnetic actuator coil 402. In some embodiments, the attracting moving plate 322 is mechanically connected to the actuating pin 302, which is mechanically connected to the actuating pin retaining plate 304, which is mechanically connected to the cam plate 306, which is mechanically connected to the cam ring 308. These mechanical connections can be locking, engaging, capturing, or just a push or pull contact. In some embodiments, as the attracting moving plate 322 moves towards the electromagnetic actuator coil 402, all of the previously mentioned mechanically connected components also move. It should be understood that not all components are necessary and components can be omitted. In some embodiments, when the cam ring 308 is pulled towards the locked half shaft gear 208, the cam plate locking feature 318 is pulled towards the locked half shaft gear locking feature 212. The cam plate locking feature 318 engages with the locked half shaft gear locking feature 212. In the locked state, the locked half shaft gear 208 is fixed relative to the in-differential drive unit housing 202. In some embodiments, the locked half shaft gear 208 is mechanically connected to the non-locked half shaft gear 206 via the planet gear 204. Thus, when in the locked state, the non-locked half shaft gear 206 is also fixed relative to the in-differential drive unit housing 202 and the locked half shaft gear 208. Thus, the corresponding first side shaft associated with the first side of the vehicle and the corresponding second side shaft associated with the second side of the vehicle are fixed.

[0071] In the locked state, the attracting moving plate 322 is pulled towards the electromagnetic actuation coil 402. For example, in some embodiments, the attracting moving plate 322 moves towards the electromagnetic actuation coil 402. In some embodiments, the attracting moving plate 322 is mechanically connected to the actuating pin 302, which is mechanically connected to the actuating pin retaining plate 304, which is mechanically connected to the cam plate 306, which is mechanically connected to the cam ring 308. These mechanical connections can be locking, engaging, capturing, or just a push or pull contact. In some embodiments, as the attracting moving plate 322 moves towards the electromagnetic actuation coil 402, all of the previously mentioned mechanically connected components also move. It should be understood that not all components are necessary and components can be omitted. In some embodiments, when the cam ring 308 is pulled towards the locked half shaft gear 208, the cam plate locking feature 318 is pulled towards the locked half shaft gear locking feature 212. The cam plate locking feature 318 engages with the locked half shaft gear locking feature 212. In the locked state, the locked half shaft gear 208 is fixed relative to the differential inner drive unit housing 202. In some embodiments, the locked half shaft gear 208 is mechanically connected to the non-locked half shaft gear 206 via the planetary gear 204. Thus, when in the locked state, the non-locked half shaft gear 206 is also fixed relative to the differential inner drive unit housing 202 and the locked half shaft gear 208. Thus, the corresponding first side shaft associated with the first side of the vehicle and the corresponding second side shaft associated with the second side of the vehicle are fixed.

[0072] Figure 6B A view of an alternative embodiment of the differential inner drive unit 200 in the locked state is shown. The differential inner drive unit 200 may also include an anti-attraction plate 324. The anti-attraction plate 324 can be made of any non-ferrous material and can include metals such as stainless steel or aluminum. The anti-attraction plate 324 can also be made of non-metallic materials such as plastics or ceramics. The anti-attraction plate 324 can be located between the attracting moving plate 322 and the differential inner drive unit housing 202. In some embodiments, due to the magnetic force acting on the attracting moving plate 322, the attracting moving plate 322 can be attracted to the differential inner drive unit housing 202. The anti-attraction plate 324 can be used to block, reduce, or mitigate the attraction between the attracting moving plate 322 and the differential inner drive unit housing 202.

[0073] Figure 7A An illustration of the electromagnetic actuation coil 402 is shown. In some embodiments, the electromagnetic actuation coil 402 includes a solenoid coil 500, a pulse width modulation (PWM) controller housing 406, and a sensor body 408. In some embodiments, the solenoid coil 500 can be located within or connected to the electromagnetic actuation coil 402. Figure 7Bis an alternative view of the electromagnetic actuator coil 402 including the integrated connector 410.

[0074] Figure 8 is a diagram of the electromagnetic actuator coil 402 having cross-sectional lines A, B, and C. Cross-sectional line A corresponds to Figure 8A , cross-sectional line B corresponds to Figure 8B , and cross-sectional line C corresponds to Figure 8C .

[0075] Figure 8A shows a portion of the electromagnetic actuator coil 402. In some embodiments, the electromagnetic actuator coil 402 includes IDC pins 412 and coil wires 414.

[0076] Figure 8B shows a portion of the electromagnetic actuator coil 402, particularly the sensor body 408 and the PWM controller housing 406. In some embodiments, the electromagnetic actuator coil 402 includes a main printed circuit board (PCB) 416, a secondary PCB 418, a magnet 420, and a Hall effect IC 422. In some embodiments, the secondary PCB 418, the magnet 420, and the Hall effect IC 422 are components of the sensor assembly 409.

[0077] Figure 8C shows a portion of the electromagnetic actuator coil 402, particularly the integrated connector 410. In some embodiments, the electromagnetic actuator coil 402 includes a connector body 424, an O-ring 426, and connector pins 428.

[0078] Figure 9A shows the solenoid coil housing 450 of the electromagnetic actuator coil 402. In some embodiments, the solenoid coil housing 450 can be circular. The solenoid coil housing 450 can be configured to capture, encapsulate, or partially encapsulate the solenoid coil 404. In some embodiments, the solenoid coil housing 450 includes a first notch 452 and a second notch 454.

[0079] As Figure 9B shown, the solenoid coil housing 450 can include lugs 456. In the illustrated embodiment, there are three lugs 456; however, there can be more or fewer lugs. The lugs 456 can include mounting holes 458 through which screws can fit. The solenoid coil housing 450 can also include a plurality of heat stake holes 460.

[0080] Figure 10Shows the solenoid coil 500 of the electromagnetic actuation coil 402. In some embodiments, the solenoid coil 500 includes a coil bobbin 502. In some embodiments, the coil bobbin 502 can be circular and shaped to hold the coil winding 504. The coil winding 504 can be potted with a thermoplastic or other adhesive or curing agent. The thermoplastic can be used to hold the windings of the coil winding 504 in place and / or bond them to each other. The thermoplastic can help the windings maintain their shape during other manufacturing steps such as injection molding or overmolding. In some embodiments, the coil bobbin 502 can also include heat melt posts 506 configured to connect with heat melt post holes 460 on the solenoid coil housing 450. In some embodiments, the solenoid coil 500 also includes a solenoid connector portion 508.

[0081] Figures 11A to 11C Shows a portion of the solenoid coil 500, particularly the solenoid connector portion 508 during the manufacturing process. Figure 11A Shows the solenoid connector portion 508 after winding. In some embodiments, the solenoid connector portion 508 includes winding posts 510 and excess leads 512. Figure 11B Shows the solenoid connector portion 508 after the IDC pins 514 are installed. Figure 11C Shows the solenoid connector portion 508 after trimming the winding posts 510 and excess leads 512.

[0082] Figure 12A Shows an exploded view of the solenoid coil 500 and the solenoid coil housing 450. In some embodiments, the solenoid coil 500 is partially encapsulated by the solenoid coil housing 450. Figure 12B Shows Figure 12A the same components, i.e., the coil assembly 550 with the solenoid coil 500 and the solenoid coil housing 450 in an assembled state.

[0083] Figure 13A Shows Figure 12B an alternative view of the solenoid coil 500 and the solenoid coil housing 450 in. In particular, the heat melt posts 506 are shown passing through the heat melt post holes 460 before performing the heat melting operation. Figure 13B Shows the heat melt posts 506 in Figure 13A after undergoing the heat melting operation.

[0084] Figure 14A Shows the components of the overmolding assembly 600. In some embodiments, the overmolding assembly 600 includes the coil assembly 550, one or more extrusion limiters 430, and connector pins 432. Figure 14BShows the overmolding assembly 600 with overmolding material 602. The overmolding material 602 can be PA66, GF30, or any other suitable material. The overmolding material 602 fills the gap between the solenoid coil housing 450, the solenoid coil 500, and other components of the overmolding assembly 600.

[0085] Figures 15A to 15C Shows a partial assembly of the electromagnetic actuating coil 402. Figure 15A Shows the main PCB 416 and the sensor assembly 409. In some embodiments, the sensor assembly 409 can be joined to the main PCB 416 via a press-fit connection. Figure 15B Shows Figure 15A The main PCB 416 and the sensor assembly 409 of are placed in the electromagnetic actuating coil 402 as shown by the arrow after assembly. More specifically, the main PCB 416 and the sensor assembly 409 are placed in the overmolding assembly 600. Figure 15C Shows the PWM controller housing cover 407 other than the overmolding assembly 600. Figure 15C The arrow in indicates the direction of the cover 407 when added to the electromagnetic actuating coil 402. In some embodiments, the PWM controller housing cover 407 is held in place by laser welding. In some embodiments, laser welding seals the PWM controller housing 406.

[0086] Figure 16A Shows a detailed view of an embodiment of the inboard drive unit 200 of the differential in the unlocked state, and Figure 16BA detailed view of an embodiment of the in-differential drive unit 200 in a locked state is shown. The attracting moving plate 322 may be a circular plate, including a base plate 326, a first wall 328, and a second wall 330. The first wall 328 may be shorter than the second wall 330. The electromagnetic actuating coil 402 may include a top side 440 that faces the inner surface 332 of the base plate 326. The electromagnetic actuating coil 402 may further include an inner ring side 442 and an outer ring side 444. The inner ring side 442 may include a first chamfered transition portion 446 that is located on the edge of the inner ring side 442 near the top side 440. The outer ring side 444 may include a second chamfered transition portion 448 that is located on the edge of the outer ring side 444 near the top side 440. The attracting moving plate 322 is separated from the electromagnetic actuating coil 402 by a gap. The gap portion between the top side 440 and the inner surface 332 may be referred to as the measurement gap 350. In the unlocked position, the measurement gap 350 may be about 5.25 mm, or may be between 5 mm and 5.5 mm, between 4.5 mm and 6 mm, between 4 mm and 6.5 mm, between 3 mm and 7.5 mm. In the locked position, the measurement gap may be about 1.25 mm, or may be between 1 mm and 1.5 mm, between 0.5 mm and 2 mm, or between 0.1 mm and 2.5 mm. The attracting moving plate 322 is separated from the electromagnetic actuating coil 402 so as not to contact in the locked state and the unlocked state.

[0087] The in-differential drive unit 200 may further include an anti-attracting plate 324. The anti-attracting plate 324 may be made of any non-ferrous material and may include a metal such as stainless steel or aluminum. The anti-attracting plate 324 may also be made of a non-metallic material such as plastic or ceramic. The anti-attracting plate 324 may be located between the attracting moving plate 322 and the in-differential drive unit housing 202. In some embodiments, due to the magnetic force acting on the attracting moving plate 322, the attracting moving plate 322 may be attracted to the in-differential drive unit housing 202. The anti-attracting plate 324 may be used to block, reduce, or mitigate the attraction between the attracting moving plate 322 and the in-differential drive unit housing 202.

[0088] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or specific fields of use disclosed. It should be understood that the components described in the present disclosure may be used outside of vehicles. The described components may be applied to aerospace, robotics, manufacturing equipment, industrial equipment, or other fields. Therefore, various alternative embodiments and / or modifications of the present disclosure (whether explicitly described or implied) are possible according to the present disclosure. In the case where embodiments of the present disclosure have been described as such, those of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Therefore, the present disclosure is limited only by the claims.

[0089] In the foregoing specification, the present disclosure has been described with reference to specific embodiments. However, as will be understood by those skilled in the art, various embodiments disclosed herein may be modified or otherwise implemented in various ways without departing from the spirit and scope of the present disclosure. Accordingly, this description should be regarded as illustrative and is intended to teach those skilled in the art the manner of making and using the various embodiments of the differential system components disclosed herein. It should be understood that the forms of the disclosure shown and described herein are to be regarded as representative embodiments. Equivalent elements, materials, processes, or steps may be substituted for those representatively shown and described herein. In addition, certain features of the present disclosure may be used independently of the use of other features, all of which will be apparent to those skilled in the art after benefiting from the description of the present disclosure. Expressions such as "comprising", "including", "combining", "consisting of", "having", "being", etc. used to describe and claim the present disclosure are intended to be understood in a non-exclusive manner, i.e., allowing the presence of items, components, or elements not explicitly described. Reference to the singular should be understood to also refer to the plural.

[0090] In addition, the various embodiments disclosed in the present disclosure should be understood as illustrative and explanatory and should not be understood as limiting the present disclosure in any way. All words indicating connection (such as attach, attach to, couple, connect, etc.) are only used to assist the reader in understanding the present disclosure and may not form a limitation, especially a limitation on the position, orientation, or use of the systems and / or methods disclosed herein. Therefore, if any, words indicating connection should be understood broadly. Moreover, these words indicating connection do not necessarily imply that two elements are directly connected. In addition, all numerical values, such as but not limited to "first", "second", "third", "primary", "secondary", "main", or any other ordinary and / or numerical values, should likewise be understood as merely identifiers used to assist the reader in understanding the various elements, embodiments, variations, and / or modifications of the present disclosure and may not form any limitation, especially a limitation on the order or preference of any element, embodiment, variation, and / or modification relative to or compared with another element, embodiment, variation, and / or modification.

[0091] It should also be understood that one or more of the elements depicted in the drawings may also be implemented in a more independent or integrated manner, or even removed or made inoperable in some cases, as these elements are useful in a particular application.

Claims

1. A differential system, comprising: a housing that defines an internal cavity; a pair of planetary gears positioned within the internal cavity and rotatably coupled to the housing; a first side gear and a second side gear positioned within the internal cavity, meshingly engaged with the planetary gears and rotatably coupled to the housing; a moving member configured to rotate with the housing and move between an engaged position and a disengaged position, wherein when the moving member is in the engaged position, the housing is drivingly coupled to the first side gear; and an electromagnetic actuator coil positioned to not rotate with the housing and configured to generate a magnetic field to move the moving member from the disengaged position to the engaged position.

2. The differential system according to claim 1, wherein the moving member further comprises: a substrate; a first wall; and a second wall.

3. The differential system according to claim 2, wherein the first wall is longer than the second wall.

4. The differential system according to claim 1, wherein the electromagnetic actuator coil does not contact the moving member.

5. The differential system according to claim 4, wherein the electromagnetic actuator coil further does not contact the housing.

6. The differential system according to claim 1, wherein when the moving member is in the engaged position and the disengaged position, the moving member is spaced apart from the electromagnetic actuator coil by a gap.

7. The differential system according to claim 6, wherein when the moving member is in the engaged position, the gap is between 0.1 mm and 2 mm.

8. The differential system according to claim 6, wherein when the moving member is in the disengaged position, the gap is between 3 mm and 7.5 mm.

9. A locking differential system, comprising: a plurality of rotating components, including: a housing that defines an internal cavity; a first side gear and a second side gear positioned within the internal cavity; and a moving member configured to move between a differential locked position and a differential unlocked position; a plurality of non-rotating components, including: an electromagnetic actuating component that does not contact the plurality of rotating components; wherein the electromagnetic actuating component interacts with the moving member to move the moving member between the differential locked position and the differential unlocked position; wherein when the moving member is in the differential locked position, the first side gear is locked relative to the second side gear.

10. The locking differential system according to claim 9, wherein the electromagnetic actuating component includes a first actuating surface, and the moving member includes a first moving member surface that faces the first actuating surface; and wherein there is a gap between the first moving member surface and the first actuating surface.

11. The locking differential system according to claim 10, wherein, at the differential unlocking position, the gap between the electromagnetic actuating member and the moving member is between 6 mm and 4 mm; and wherein, at the differential locking position, the gap between the electromagnetic actuating member and the moving member is between 2 mm and 0.1 mm.

12. The locking differential system according to claim 9, wherein, the first side gear is connected to a first drive shaft, and the second side gear is connected to a second drive shaft.

13. The locking differential system according to claim 9, wherein, the plurality of rotating members further includes: a cam ring, the cam ring being connected to the moving member; wherein, when the moving member is in the differential locking position, the cam ring directly engages the first side gear.

14. The locking differential system according to claim 9, wherein, the moving member is made of ferromagnetic metal.

15. A locking differential system, comprising: a housing that defines an internal cavity, the housing having a rotational axis; a first gear and a second gear, the first gear and the second gear being positioned within the internal cavity and capable of rotating about the rotational axis; a moving member configured to rotate with the housing and move in a direction parallel to the rotational axis; and an attracting element configured to move the moving member; wherein, the attracting element does not contact the moving member.

16. The locking differential system according to claim 15, wherein, in the differential locking state and the differential unlocking state, the attracting element does not contact the housing, the first gear, or the second gear.

17. The locking differential system according to claim 15, wherein, the moving member includes a first wall configured to interact with the attracting element.

18. The locking differential system according to claim 17, wherein, the moving member further includes a second wall configured to interact with the attracting element.

19. The locking differential system according to claim 18, wherein, the first wall is longer than the second wall.

20. The locking differential system according to claim 18, wherein, when the differential is in the locked state, the first wall and the second wall at least partially surround the attracting element.

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