A working condition simulation platform for displaying a torsen differential in a four-wheel drive system

Abstract

This invention discloses a platform for simulating the working conditions of a Torsen differential in a four-wheel drive system, relating to the field of automotive teaching aids technology. The platform includes: a platform frame; a four-wheel drive transmission simulation unit comprising a drive motor, a Torsen center differential driven by the drive motor, connected front and rear axle drive shafts, and four rotary output ends; a wheel load simulation unit for applying rotational resistance to the rotary output ends; a working condition preset and control unit for automatically controlling the four wheel load simulation units to apply preset resistance combinations corresponding to the working condition mode; a data display unit for real-time display of speed and torque data at the rotary output ends; and a differential lock actuator for achieving rigid connection and synchronous rotation of the front and rear axle drive shafts. The beneficial effect of this invention is that it transforms complex mechanical principles, systematic engineering logic, and cutting-edge automotive technology into intuitive and operable teaching practices, possessing significant promotional value and application prospects.

Description

Technical Field

[0001] This invention relates to the field of automotive teaching aids technology, specifically to a platform for simulating the working conditions of a Torsen differential in a four-wheel drive system. Background Technology

[0002] The Torsen differential, a torque-sensing limited-slip differential based on the worm gear self-locking principle, is one of the core components for intelligent torque distribution in all-wheel-drive vehicles. It can automatically and steplessly adjust the torque distribution between the front and rear axles or between the left and right wheels according to driving conditions, significantly improving the vehicle's traction, passability, and handling stability. Therefore, understanding the structural principles of the Torsen differential and its working logic within the vehicle system is an important part of the curriculum for vehicle engineering, automotive service engineering, and other related majors.

[0003] Currently, in the teaching and practical training of related courses, commonly used teaching aids mainly include physical cross-sectional models, two-dimensional principle animation videos, simple demonstration stands, and physical vehicles or assemblies. However, these existing technical means have obvious limitations in achieving in-depth, systematic, and interactive teaching: (1) the demonstration methods are static and isolated; (2) physical cross-sectional models can only show the internal gear structure and cannot dynamically demonstrate the real-time torque distribution process; (3) they have limited functions and cannot simulate complex real working conditions; (4) they lack quantitative data and interactive inquiry, and advanced simulation equipment is expensive and unfocused. Students cannot observe the working characteristics of the Torsen differential and its mechanical and physical limits through experiments, and they cannot understand how it works in conjunction with the electronic stability control system to achieve escape from trouble, resulting in a serious lack of teaching depth. Summary of the Invention

[0004] To address the above shortcomings, this invention provides a simulation platform for demonstrating the working conditions of the Torsen differential in a four-wheel drive system, thereby solving the problem of demonstrating the Torsen differential under different working conditions in a four-wheel drive system.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A platform for simulating the operating conditions of a Torsen differential in a four-wheel drive system includes: Platform framework; The four-wheel drive transmission simulation unit includes a drive motor, a Torsen center differential driven by the drive motor, a front axle drive shaft and a rear axle drive shaft connected to the front output shaft and the rear output shaft of the Torsen center differential, respectively, and four rotary output ends driven by the front axle drive shaft and the rear axle drive shaft, respectively, for the left front wheel, right front wheel, left rear wheel and right rear wheel. There are four wheel load simulation units, which are connected one-to-one with the four rotary output terminals and are used to apply independently adjustable rotational resistance to the corresponding rotary output terminals. The working condition preset and control unit is communicatively connected to the four wheel load simulation units. It has multiple standard working condition modes pre-stored in its contents. The working condition preset and control unit is used to automatically control the four wheel load simulation units to apply a preset resistance combination corresponding to the working condition mode selected by the user. The data display unit is used to display the rotational speed and torque data of the four rotary output terminals in real time; In addition, a differential lock actuator is used to achieve rigid connection and synchronous rotation of the front axle drive shaft and the rear axle drive shaft, and the differential lock actuator is communicatively connected to the operating condition preset and control unit.

[0006] Furthermore, the wheel load simulation unit includes a magnetic powder brake and a sensor for measuring the rotational speed and torque of the corresponding rotating output end; the magnetic powder brake can be continuously, accurately, and quickly adjusted between 0 and rated torque by changing the excitation current through the controller to simulate different adhesion forces, while the sensor collects the torque and rotational speed signals of the "wheel" in real time.

[0007] Furthermore, the working condition preset and control unit includes a working condition selection knob with multiple gear indicators. The gear indicators include at least "straight driving", "cornering", "single axle slip" and "cross axle slip". For example, when "cross axle slip" is selected, the PLC will output a near-zero current to the magnetic powder brake that controls the load of the left front wheel and the right rear wheel to simulate suspension, while outputting a higher current to the brakes of the right front wheel and the left rear wheel to simulate good adhesion.

[0008] Furthermore, the differential lock actuator includes a linear actuator, a shift fork driven by the linear actuator, and a dog clutch controlled by the shift fork to engage or disengage; the dog clutch is located between the front axle drive shaft and the rear axle drive shaft; in the default state, the linear actuator is in the retracted position, the shift fork disengages the dog clutch, and the power between the front and rear axles is normally distributed through the Torsen differential; when a command is received to extend, the linear actuator pushes the shift fork, which moves the driven part of the dog clutch forward, causing its teeth to mesh with the driving part, thereby achieving a completely rigid connection between the front and rear axle drive shafts.

[0009] Furthermore, it also includes a differential lock status sensor, used to detect the engagement and disengagement status of the dog clutch and feed back the status signal to the operating condition preset and control unit; the differential lock status sensor is used to detect the clutch position in real time and feed back the information.

[0010] Furthermore, the four-wheel drive simulation unit also includes a front wheel open differential connected to the front axle driveshaft and a rear wheel open differential connected to the rear axle driveshaft.

[0011] Furthermore, the data display unit includes a display screen that shows the power distribution path from the front axle to the rear axle via the Torsen center differential in a dynamic schematic form, and displays the torque distribution ratio between the front axle and the rear axle in numerical form.

[0012] This invention provides a simulation platform for demonstrating the working conditions of the Torsen differential in a four-wheel drive system. It offers the following advantages: by placing the Torsen differential in its actual operating system environment, it not only demonstrates the structure and working principle of the Torsen differential independently, but also comprehensively simulates various complex working conditions faced by the Torsen differential as a central differential in a full-time four-wheel drive vehicle, such as straight lines, curves, single-axle slippage, and cross-axle situations. This completely changes the traditional teaching method where components and systems are disconnected. Through load change simulation, students can intuitively understand how the differential receives vehicle status signals and how it outputs torque distribution commands to affect the vehicle's dynamics, forming a complete knowledge loop. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of a platform for simulating the working conditions of a Torsen differential in a four-wheel drive system, as described in this invention. Figure 2 This is a schematic diagram of the four-wheel drive transmission simulation unit described in this invention; Figure 3 This is a cross-sectional view of the Torsen center differential described in this invention; Figure 4 This is a schematic diagram of the rear axle driveshaft described in this invention; Figure 5 This is a schematic diagram of the wheel load simulation unit described in this invention; Figure 6 This is a schematic diagram of the differential lock actuator described in this invention; Figure 7 This is a schematic diagram of the simulation platform framework process described in this invention; In the diagram: 1. Platform frame; 2. Four-wheel drive simulation unit; 21. Drive motor; 22. Torsen center differential; 23. Front output shaft; 24. Rear output shaft; 25. Front axle driveshaft; 251. Front wheel open differential; 26. Rear axle driveshaft; 261. Rear wheel open differential; 27. Rotary output end; 3. Wheel load simulation unit; 31. Magnetic powder brake; 32. Speed ​​and torque sensors; 4. Operating condition preset and control unit; 41. Operating condition selection knob; 5. Data display unit; 51. Display screen; 6. Differential lock actuator; 61. Linear actuator; 62. Shift fork; 63. Jaw clutch; 64. Differential lock status sensor. Detailed Implementation

[0014] The present invention will now be described in detail with reference to the accompanying drawings, such as... Figure 1-7As shown: This application embodiment provides a simulation platform for demonstrating the working conditions of a Torsen differential in a four-wheel drive system, including: a platform base frame 1; a four-wheel drive transmission simulation unit 2, which includes a drive motor 21, a Torsen center differential 22 driven by the drive motor 21, a front axle drive shaft 25 and a rear axle drive shaft 26 respectively connected to the front output shaft 23 and the rear output shaft 24 of the Torsen center differential 22, and four rotating output terminals 27 driven by the front axle drive shaft 25, the right front wheel, the left rear wheel, and the right rear wheel respectively through the front axle drive shaft 25 and the rear axle drive shaft 26; and four wheel load simulation units 3, each corresponding to one of the four rotating output terminals 27, for transmitting loads to the corresponding rotating wheels. The rotary output end 27 applies an independently adjustable rotational resistance; the working condition preset and control unit 4 is communicatively connected to the four wheel load simulation units 2, and has multiple standard working condition modes pre-stored in it. The working condition preset and control unit 4 is used to automatically control the four wheel load simulation units 3 to apply a preset resistance combination corresponding to the working condition mode selected by the user; the data display unit 5 is used to display the speed and torque data of the four rotary output ends 27 in real time; and the differential lock actuator 6 is used to realize the rigid connection and synchronous rotation of the front axle drive shaft 25 and the rear axle drive shaft 26, and the differential lock actuator 6 is communicatively connected to the working condition preset and control unit 4.

[0015] In this embodiment, the platform is mounted on a stable platform frame 1 constructed from industrial aluminum profiles, with a clear layout that facilitates observation and operation. The drive motor 21 serves as the power source, and its output shaft is rigidly connected to the input end of a Torsen center differential 22 via a reducer. The front and rear output shafts of the Torsen center differential 22 are connected to the front axle drive shaft 25 and the rear axle drive shaft 26, respectively. The end of the front axle drive shaft 25 is connected to a front wheel open differential, and the end of the rear axle drive shaft 26 is connected to a rear wheel open differential. The left and right output half-shafts of each wheel differential ultimately drive four rotating output flanges (left front, right front, left rear, and right rear), i.e., rotating output ends 27, respectively. Four wheel load simulation units 3 are connected one-to-one with the four rotating output ends 27, used to simulate the load of the wheels. The corresponding rotary output terminal 27 applies independently adjustable rotational resistance; the working condition preset and control unit 4 is the brain of the platform, and its hardware core is an embedded PLC controller. The panel has a multi-level working condition selection knob, clearly marked with icons such as "straight driving", "right turn", "front axle slip", and "cross axle". The PLC has pre-stored the optimized combination of target resistance values ​​for the four wheels corresponding to each working condition; the data display unit 5 includes a large-size touch screen, and its software interface is divided into three areas: the left side is a dynamic power flow diagram, which uses animated arrows to display the power distribution path through the Torsen differential and differential lock in real time; the center is the digital instrument area, which displays the front and rear axle torque distribution ratio and the real-time speed / torque of each wheel; the right side is the curve area, which plots the changing trend of key parameters over time.

[0016] Step 1: Observation of basic principles; The teacher turns the operating condition knob to "straight driving". The PLC automatically sets the four loads to the same value and starts the drive motor 21 at low speed. Students can see from the display screen that the torque is stably distributed as 50:50 and the power flow animation is smooth. Turning to "right turn", the system automatically increases the load on the left front and left rear wheels to simulate centrifugal force. Students observe that while there is a speed difference between the left and right wheels, the torque automatically shifts slightly to the right wheel, thus understanding Torsen's pre-locking and active distribution characteristics.

[0017] Step 2: Demonstration of single-axle failure and self-rescue; when the knob is turned to "front axle slippage", the system adjusts the load on the two front axle wheels to the minimum. Students can observe that at the moment the front wheels spin freely, the power is quickly transferred to the rear axle through the self-locking effect of the Torsen center differential 22. The rear wheels receive most of the torque and rotate, and the vehicle "gets out of trouble". This process demonstrates Torsen's core advantages.

[0018] Step 3: Teaching the comparison between extreme working conditions and mechanical locking; Pure mechanical mode: The teacher turns the knob to "cross axis". The PLC automatically sets the left front and right rear wheels to low load and the right front and left rear wheels to high load. The system is started. The students can clearly observe that in the pure Torsen working state, due to the limited self-locking coefficient, the power circulates between the two wheels with traction and cannot form an effective driving force, simulating the vehicle being "stuck". On the data display screen, the torque of the front and rear axles fluctuates violently but cannot get out of trouble.

[0019] Manual locking intervention: At this time, the teacher presses the "differential lock engagement" button on the control panel. The PLC controls the cylinder to move, driving the jaw clutch to engage with a "click". Students immediately see from the display screen and the actual rotation of the drive shaft that the front and rear axles are rigidly connected and rotate synchronously. Instantly, all power is forced to the right front wheel and left rear wheel with traction, and the vehicle successfully "gets out of trouble". At the same time, the power flow diagram on the screen changes into a thick solid line running through the front and rear, which is in stark contrast to the previous dynamic distribution.

[0020] Lockout and Restoration to Normal: After escaping the obstacle, the instructor presses the "Differential Lock Disengagement" button. The cylinder retracts, the clutch disengages, and the system returns to the intelligent distribution state of the Torsen differential. This complete process profoundly illustrates the application scenarios and synergistic relationship between "automatic limited slip" and "manual locking."

[0021] In some embodiments, the wheel load simulation unit 3 includes a magnetic powder brake 31 and a sensor 32 for measuring the rotational speed and torque of the corresponding rotating output end. The magnetic powder brake 31 can be continuously, accurately and quickly adjusted between 0 and rated torque by changing the excitation current through the controller to simulate different adhesion forces. The sensor collects the torque and rotational speed signals of the "wheel" in real time.

[0022] In some embodiments, the working condition preset and control unit 4 includes a working condition selection knob 41 with multiple gear indicators, the gear indicators including at least "straight driving", "cornering", "single axle slip" and "cross axle slip"; when "cross axle slip" is selected, the PLC will output a near-zero current to the magnetic powder brake 31 that controls the load of the left front wheel and the right rear wheel to simulate suspension, while outputting a higher current to the brakes of the right front wheel and the left rear wheel to simulate good adhesion.

[0023] In some embodiments, the differential lock actuator 6 includes a linear actuator 61, a shift fork 62 driven by the linear actuator 61, and a jaw clutch 63 controlled by the shift fork 62 to engage or disengage. The jaw clutch 63 is disposed between the front axle driveshaft 25 and the rear axle driveshaft 26. The linear actuator 61 is a cylinder. In the default state, the cylinder is in the retracted position, and the shift fork 62 disengages the jaw clutch 63. The power between the front and rear axles is normally distributed through the Torsen differential. When the cylinder 61 receives a command to extend, it pushes the shift fork 62. The shift fork 62 moves the driven part of the jaw clutch 63 forward, so that its teeth mesh with the driving part, thereby achieving a completely rigid connection between the front and rear axle driveshafts.

[0024] In some embodiments, a differential lock status sensor 64 is also included, which is used to detect the engagement and disengagement status of the jaw clutch 63 and feed back the status signal to the operating condition preset and control unit 4; a differential lock status sensor 61 is used to detect the clutch position in real time and feed back the information.

[0025] In some embodiments, the four-wheel drive simulation unit 2 further includes a front wheel open differential 251 connected to the front axle driveshaft 25 and a rear wheel open differential 261 connected to the rear axle driveshaft 26.

[0026] In some embodiments, the data display unit 5 includes a display screen 51, which displays the power distribution path from the front axle to the rear axle via the Torsen center differential 22 in a dynamic schematic form and displays the torque distribution ratio between the front axle and the rear axle in numerical form.

[0027] The above technical solutions only embody the preferred technical solutions of the present invention. Any modifications that may be made by those skilled in the art to certain parts thereof embody the principles of the present invention and fall within the protection scope of the present invention.

Claims

1. A platform for simulating the operating conditions of a Torsen differential in a four-wheel drive system, characterized in that, include: Platform base frame (1); The four-wheel drive simulation unit (2) includes a drive motor (21), a Torsen center differential (22) driven by the drive motor (21), a front axle drive shaft (25) and a rear axle drive shaft (26) respectively connected to the front output shaft (23) and the rear output shaft (24) of the Torsen center differential (22), and four rotary output ends (27) driven by the front axle drive shaft (25), the right front wheel, the left rear wheel and the right rear wheel respectively through the front axle drive shaft (25) and the rear axle drive shaft (26). There are four wheel load simulation units (3), which are connected one-to-one with the four rotary output terminals (27) to apply independently adjustable rotational resistance to the corresponding rotary output terminals (27); The working condition preset and control unit (4) is connected to the four wheel load simulation units (2) and has multiple standard working condition modes pre-stored in it. The working condition preset and control unit (4) is used to automatically control the four wheel load simulation units (3) to apply a preset resistance combination corresponding to the working condition mode according to the working condition mode selected by the user. The data display unit (5) is used to display the rotational speed and torque data of the four rotary output terminals (27) in real time; In addition, the differential lock actuator (6) is used to realize the rigid connection and synchronous rotation of the front axle drive shaft (25) and the rear axle drive shaft (26), and the differential lock actuator (6) is communicatively connected to the working condition preset and control unit (4).

2. The platform for simulating the working conditions of the Torsen differential in a four-wheel drive system according to claim 1, characterized in that, The wheel load simulation unit (3) includes a magnetic powder brake (31) and a sensor (32) for measuring the rotational speed and torque of the corresponding rotational output end.

3. The platform for simulating the working conditions of the Torsen differential in a four-wheel drive system according to claim 1, characterized in that, The working condition preset and control unit (4) includes a working condition selection knob (41) with multiple gear indicators, the gear indicators including at least "straight driving", "cornering driving", "single axle slip" and "cross axle slip".

4. The platform for simulating the working conditions of the Torsen differential in a four-wheel drive system according to claim 1, characterized in that, The differential lock actuator (6) includes a linear actuator (61), a shift fork (62) driven by the linear actuator (61), and a dog clutch (63) controlled by the shift fork (62) to engage or disengage; the dog clutch (63) is located between the front axle drive shaft (25) and the rear axle drive shaft (26).

5. The platform for simulating the working conditions of the Torsen differential in a four-wheel drive system according to claim 4, characterized in that, It also includes a differential lock status sensor (64) for detecting the engagement and disengagement status of the jaw clutch (63) and feeding back the status signal to the operating condition preset and control unit (4).

6. The teaching simulation platform according to claim 1, characterized in that, The four-wheel drive simulation unit (2) also includes a front wheel open differential (251) connected to the front axle drive shaft (25) and a rear wheel open differential (261) connected to the rear axle drive shaft (26).

7. The platform for simulating the working conditions of the Torsen differential in a four-wheel drive system according to claim 1, characterized in that, The data display unit (5) includes a display screen (51), which displays the power distribution path from the Torsen center differential (22) to the front and rear axles in a dynamic schematic form and displays the torque distribution ratio between the front and rear axles in numerical form.

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