Position sensor for a locking differential

Abstract

A limited-slip differential can be an electrically operated limited-slip differential to which a bushing and an annular position sensor are fixed. The bushing and the annular position sensor can move axially relative to an actuating side housing of the electrically operated limited-slip differential. A target ring can be fixed to the actuating side housing. The target ring can be in a fixed axial position relative to a locking axle gear. The annular position sensor can be in a fixed axial position relative to a clutch disc. The annular position sensor can determine a relative axial position between itself and the target ring. This relative axial position can indicate the relative axial position between the clutch disc and the locking axle gear, thus indicating whether the electrically operated limited-slip differential is locked or unlocked.

Description

Technical field

[0001] The present disclosure relates generally to differentials and in particular to locking differentials. background

[0002] Differential gears can include bevel gears with orbital motion. The bevel gears can mesh with axle gears. The axle gears can be unlocked to allow differential rotation, or they can be locked together to prevent differential rotation. Difficulties can arise when a sensor device is provided to detect whether the axle gears are unlocked or locked. Therefore, it would be advantageous to provide a device, system, and method that overcomes the shortcomings described above. Brief description

[0003] An electric locking differential according to one or more embodiments of the present disclosure is described. The electric locking differential may include: a final drive gear, wherein the final drive gear includes an external helical gear and a flange, the flange being arranged radially inside the external helical gear and axially aligned with it; an actuating side housing, wherein the actuating side housing is fixed to the flange, the final drive gear and the actuating side housing being configured to rotate together about a central axis; a target ring, wherein the target ring is fixed to the actuating side housing; a bushing, wherein the bushing and the actuating side housing are coupled by a rotary pushrod joint;and an annular position sensor, wherein the socket and the annular position sensor are fixed, the annular position sensor being configured to detect a relative axial position between the annular position sensor and the target ring, the relative axial position between the annular position sensor and the target ring indicating that the electrical locking differential is configured in an unlocked configuration or a locked configuration.

[0004] In some aspects, the ring-shaped position sensor includes one or more inductive position sensors.

[0005] In some aspects, the bushing includes an axial section and a radial section, wherein the radial section extends radially outwards from the axial section, the axial section forming the rotary push-joint with the actuating side housing, the annular position sensor being axially aligned with the axial section of the bushing and arranged radially outside to it, the annular position sensor being radially aligned with the radial section of the bushing.

[0006] In some aspects, the electric locking differential includes an electromagnet, wherein the actuating side housing is made of an iron-containing material, wherein the electromagnet configures the electric locking differential to change from the unlocked configuration to the locked configuration when the electromagnet is activated, wherein the bushing, the electromagnet and the annular position sensor are fixed, and wherein the electromagnet, the bushing and the annular position sensor do not rotate together with the final drive gear and the actuating side housing.

[0007] In some aspects, the electromagnet is arranged radially outside the socket, axially aligned with it, and fixed to it.

[0008] In some aspects, the electric locking differential includes a bearing coupled to the actuating side housing, wherein the bearing is coupled to the actuating side housing, wherein the bearing is radially aligned with the bushing, and wherein the target ring is arranged axially between the bearing and the annular position sensor.

[0009] In some aspects, the electric locking differential includes a locking axle gear, wherein an axial position of the target ring relative to the locking axle gear is defined; and a clutch disc, wherein the clutch disc and the locking axle gear form a dog clutch in the locked configuration, wherein an axial position of the clutch disc relative to the annular position sensor is defined.

[0010] In some aspects, the electric limited-slip differential includes a bevel gear set, wherein the bevel gear set comprises a plurality of bevel gears, the plurality of bevel gears being fixed to the flange, the final drive gear and the bevel gear set being configured to rotate together about the central axis, the plurality of bevel gears being orthogonal to the central axis and rotating about it via an orbital motion; and an axle shaft gear, wherein the axle shaft gear and the limited-slip axle shaft gear are coupled to the plurality of bevel gears, the bevel gear set being arranged axially between the axle shaft gear and the limited-slip axle shaft gear, the axle shaft gear and the limited-slip axle shaft gear rotating independently of each other in the unlocked configuration, the axle shaft gear and the limited-slip axle shaft gear rotating together in the locked configuration.

[0011] In some aspects, the flange defines a plurality of recessed sections, wherein the bevel gear set includes a plurality of pins, wherein the plurality of pins and the plurality of bevel gears are fixed to one another, wherein the plurality of pins is arranged within and abuts the plurality of recessed sections, wherein the plurality of pins and the plurality of bevel gears are orthogonal to the central axis and rotate about it via an orbital motion.

[0012] In some aspects, the electric locking differential includes a return spring, the return spring being configured to return the clutch disc from the locked configuration to the unlocked configuration.

[0013] In some cases, the locking axle gear, the return spring and the clutch disc are arranged radially inside the actuating side housing and aligned axially with it.

[0014] In some aspects, the electric locking differential includes a thrust bearing and a plurality of actuating pins, wherein the plurality of actuating pins rotates together with the actuating side housing, wherein the plurality of actuating pins is arranged axially between the thrust bearing and the coupling plate, radially aligned and coupled thereto, wherein the thrust bearing is arranged axially between the bushing and the plurality of actuating pins, radially aligned and coupled thereto.

[0015] In some aspects, the thrust bearing is coupled to a radial section of the bushing.

[0016] In some cases, the thrust bearing couples an axial displacement between the bushing and the plurality of actuating pins without coupling the rotation of the final drive gear through the actuating side housing and the plurality of actuating pins to the bushing.

[0017] In some aspects, the multitude of actuating pins is configured to move through a radial section of the actuating side housing.

[0018] In some aspects, the electric locking differential includes an inner housing, the inner housing being fixed between the flange and the actuating side housing, with the coupling plate and the inner housing being coupled by a splined connection.

[0019] In some aspects, the electric locking differential includes a retaining ring, with the return spring arranged axially between the retaining ring and the clutch disc, radially aligned and coupled to it, the retaining ring being fixed to the inner housing.

[0020] In some aspects, the flange, the inner housing and the actuator side housing are fixed together by a variety of fasteners or a weld.

[0021] A drive train according to one or more embodiments of the present disclosure is described. The drive train may include: an electric locking differential with a final drive gear, wherein the final drive gear includes an external helical gear and a flange, the flange being arranged radially inside the external helical gear and axially aligned with it; an actuating side housing, wherein the actuating side housing is fixed to the flange, the final drive gear and the actuating side housing being configured to rotate together about a central axis; a target ring, wherein the target ring is fixed to the actuating side housing; a bushing, wherein the bushing and the actuating side housing are coupled by a rotary push-fit joint; a bushing, wherein the bushing and the actuating side housing are coupled by a cylindrical connection;and an annular position sensor, wherein the bushing and the annular position sensor are fixed, the annular position sensor being configured to detect a relative axial position between the annular position sensor and the target ring, the relative axial position between the annular position sensor and the target ring indicating whether the electrical locking differential is configured in an unlocked or locked configuration; a motor; and a gearbox, the gearbox coupling a torque from the motor to the final drive gear.

[0022] In some aspects, the drivetrain includes a pair of axles, wherein the electric locking differential includes a drive shaft gear and a locking drive shaft gear, wherein the pair of axles is coupled by an internal spline connection of the drive shaft gear and the locking drive shaft gear; and a pair of driven wheels coupled to the pair of axles, wherein the drive shaft gear, the locking drive shaft gear, the pair of axles and the pair of driven wheels are configured to rotate about the central axis. Brief description of the drawings

[0023] The numerous advantages of the disclosure can be better understood by experts by referring to the accompanying illustrations, which: Fig. 1A represents a perspective view of an electrical locking differential according to one or more embodiments of the present disclosure. Fig. 1B represents the perspective view of the electrical locking differential with concealed bearings according to one or more embodiments of the present disclosure. Fig. Figure 1C shows a cross-sectional view of the electrical locking differential according to one or more embodiments of the present disclosure. Fig. Figure 1D shows a cross-sectional view of the electrical locking differential in a locked configuration according to one or more embodiments of the present disclosure. Fig. 1E represents a partial cross-section of the electrical locking differential in the locked configuration according to one or more embodiments of the present disclosure. Fig. 1F represents a partial cross-section of the electrical locking differential in the locked configuration according to one or more embodiments of the present disclosure. Fig. Figure 1G represents a cross-sectional view of the electrical locking differential in an unlocked configuration according to one or more embodiments of the present disclosure. Fig. 1H represents a partial cross-section of the electrical locking differential in the unlocked configuration according to one or more embodiments of the present disclosure. Fig. 1I represents an exploded view of the electrical locking differential according to one or more embodiments of the present disclosure. Fig. 1J represents a perspective view of a locking axle shaft wheel of the electric locking differential according to one or more embodiments of the present disclosure. Fig. 2 a simplified diagram of a drive train with an electric locking differential according to one or more embodiments of the present disclosure. Detailed description

[0024] Embodiments of the present disclosure are described herein. It is understood, however, that the disclosed embodiments are merely examples and that other embodiments may have different and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of components. Therefore, certain constructive and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching the person skilled in the art to apply the embodiments in various ways. As those skilled in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to create embodiments that are not expressly illustrated or described.The illustrated combinations of features provide representative embodiments for typical applications. However, various combinations and modifications of the features, consistent with the teachings of this disclosure, may be desirable for specific applications or implementations.

[0025] Embodiments of the present disclosure relate to a position sensor for a limited-slip differential. The limited-slip differential can be an electric limited-slip differential to which a bushing and an annular position sensor are fixed. The bushing and the annular position sensor can displace axially relative to an actuating side housing of the electric limited-slip differential. A target ring can be fixed to the actuating side housing. The target ring can be located in a fixed axial position relative to a locking axle gear. The annular position sensor can be located in a fixed axial position relative to a clutch disc. The annular position sensor can determine a relative axial position between itself and the target ring.The relative axial position can indicate a relative axial position between the clutch disc and the locking axle shaft gear, thus indicating whether the electric locking differential is locked or unlocked.

[0026] Fig. 1A-1J represent an electric locking differential 100 according to one or more embodiments of the present disclosure. The electric locking differential 100 may include a final drive gear 102, a bevel gear set 104, an axle shaft gear 106, a locking axle shaft gear 108, a retaining ring 110, a return spring 112, a clutch disc 114, actuating pins 116, a thrust bearing 118, a bushing 120, an electromagnet 122, a side housing 124, an inner housing 126, an actuating side housing 128, a bearing 130, a bearing 131, fastening elements 132, an annular position sensor 178 and / or a target ring 180.

[0027] The central axis of the electric locking differential 100, the final drive gear 102, the bevel gear set 104, the axle shaft gear 106, the locking axle shaft gear 108, the retaining ring 110, the return spring 112, the clutch disc 114, the thrust bearing 118, the bushing 120, the electromagnet 122, the side housing 124, the inner housing 126, the actuating side housing 128, the bearing 130 and / or the bearing 131 may coincide. The actuating pins 116 and / or fastening elements 132 may be radially offset from the central axis of the electric locking differential 100.

[0028] The electric locking differential 100 can be configured in an unlocked configuration and / or a locked configuration. The unlocked configuration and the locked configuration can also be referred to as open configuration and closed configuration, respectively.

[0029] The final drive gear 102, the bevel gear set 104, the actuating pins 116, the side housing 124, the inner housing 126, and / or the actuating side housing 128 can be configured to rotate together around the central axis of the electric locking differential 100. The final drive gear 102, the bevel gear set 104, the actuating pins 116, the side housing 124, the inner housing 126, and / or the actuating side housing 128 can rotate together when the electric locking differential 100 is in the unlocked configuration and / or in the locked configuration.

[0030] The axle shaft gear 106 and / or the locking axle shaft gear 108 can also rotate about the central axis of the electric locking differential 100. The relative rotational speed of the axle shaft gear 106 and / or the locking axle shaft gear 108 can depend on whether the electric locking differential 100 is configured in the unlocked or locked configuration.

[0031] When the electric limited-slip differential 100 is in the unlocked configuration, the axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 can rotate about the central axis of the electric limited-slip differential 100 independently of the final drive gear 102, the bevel gear set 104, the actuating pins 116, the side housing 124, the inner housing 126, and / or the actuating side housing 128. The axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 can also rotate independently of each other when the electric limited-slip differential 100 is in the unlocked configuration. This independent rotation of the axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 when the electric limited-slip differential 100 is in the unlocked configuration allows for differential rotation of the axle shaft sprocket 106 and the locking axle shaft sprocket 108.

[0032] When the electric limited-slip differential 100 is in the locked configuration, the axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 can rotate about the central axis of the electric limited-slip differential 100 together with the final drive gear 102, the bevel gear set 104, the actuating pins 116, the side housing 124, the inner housing 126, and / or the actuating side housing 128. The axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 can also rotate together when the electric limited-slip differential 100 is in the locked configuration. The locking axle shaft sprocket 108 can prevent differential, so that the axle shaft sprocket 106 and the locking axle shaft sprocket 108 rotate at the same speed.

[0033] The final drive gear 102 can include an external helical gear 134 and / or a flange 136. The external helical gear 134 can point outwards away from the central axis of the final drive gear 102. The external helical gear 134 can include teeth arranged at a specific angle to the central axis of the final drive gear 102. The final drive gear 102 can be configured to receive torque via the external helical gear 134. The flange 136 can be arranged radially inside the external helical gear 134 and thus be axially aligned. The flange 136 can be annular and have a hole in the central axis of the final drive gear 102. The flange 136 can define recessed sections 138. The recessed sections 138 can be defined axially by the flange 136. The recessed sections 138 can extend radially outwards from the central axis of the final drive gear 102.The recessed sections 138 can open radially inwards.

[0034] The bevel gear set 104 can include pins 140, bevel gears 142, and / or a central section 144. The bevel gear set 104 can be a rigid body. The pins 140, the bevel gears 142, and / or the central section 144 can be fixed to one another in such a way that they cannot rotate and / or displace relative to each other. For example, the pins 140 can be fixed to one another via the central section 144. The bevel gears 142 can be fixed to the respective pins 140. The central section 144 can coincide with the central axis of the electric locking differential 100. The pins 140 can coincide with and / or be arranged within the respective bevel gears 142. A central axis of the pins 140 and / or the bevel gears 142 can run orthogonally to the central axis of the electrical locking differential 100.The pins 140 and / or the bevel gears 142 must not rotate about the central axis of the bevel gears 142. Instead, the pins 140 and / or the bevel gears 142 may rotate about the central axis of the electric locking differential 100. In this way, the pins 140 and / or the bevel gears 142 may rotate about the central axis of the bevel gear set 104 by means of an orbital motion.

[0035] The pins 140 can be arranged within and rest against the recessed sections 138. The final drive gear 102 can be configured to transmit the torque received from the external helical gear 134 through the flange 136 and via the recessed sections 138 to the bevel gear set 104. The pins 140 can receive the torque from the final drive gear 102 and rotate with the final drive gear 102 as a rigid body.

[0036] The electric locking differential 100 can include a suitable number of recessed sections 138, pins 140, and bevel gears 142. The electric locking differential 100 can include any number of recessed sections 138, pins 140, and bevel gears 142. For example, the electric locking differential 100 can include two, three, four, or more of the recessed sections 138, the pins 140, and the bevel gears 142. As shown, the electric locking differential 100 includes three of the recessed sections 138, the pins 140, and the bevel gears 142, although this is not intended as a limitation.

[0037] The recessed sections 138, the pins 140, and the bevel gears 142 can be offset circumferentially relative to their adjacent recessed sections 138, pins 140, and bevel gears 142. In embodiments, each of the recessed sections 138, pins 140, and bevel gears 142 is offset circumferentially relative to its adjacent recessed sections 138, pins 140, and bevel gears 142 by the same angle. For example, the recessed sections 138, pins 140, and bevel gears 142 can be arranged in a polar array. The angle can be determined by the number of recesses 138, pins 140, and bevel gears 142.As shown, each of the recessed sections 138, pins 140 and bevel gears 142 is offset circumferentially from the adjacent recessed sections 138, pins 140 and bevel gears 142 by an angle of 120°, although this is not intended as a restriction and may vary depending on the number of recessed sections 138, pins 140 and bevel gears 142.

[0038] The axle shaft gear 106 and the locking axle shaft gear 108 can be arranged on opposite axial sides of the bevel gear set 104. The bevel gear set 104 can be arranged axially between the axle shaft gear 106 and the locking axle shaft gear 108.

[0039] The axle shaft gear 106 and / or the locking axle shaft gear 108 can be coupled to the bevel gear set 104. The axle shaft gear 106 and / or the locking axle shaft gear 108 can be coupled to the bevel gears 142 of the bevel gear set 104. The axle shaft gear 106 and / or the locking axle shaft gear 108 can mesh with the bevel gears 142. The bevel gear set 104 can be configured to transmit the torque received by the bolts 140 via the bevel gears 142 to the axle shaft gear 106 and / or the locking axle shaft gear 108 via the gear mesh.

[0040] The axle shaft gear 106 and / or the differential axle shaft gear 108 can be coupled to the bevel gears 142 in a crossed arrangement. For example, the central axis of the bevel gears 142 can be orthogonal to the axle shaft gear 106 and / or the differential axle shaft gear 108. The axle shaft gear 106, the differential axle shaft gear 108, and / or the bevel gears 142 can have selected helix angles to provide the crossed arrangement. The helix angles of the axle shaft gear 106 and / or the differential axle shaft gear 108 can be the same. The helix angles of the bevel gears 142 can be the same. The helix angles of the axle shaft gear 106 and / or the differential axle shaft gear 108 may or may not match the helix angles of the bevel gears 142.

[0041] The axle shaft gear 106 and / or the limited-slip axle shaft gear 108 can include an external bevel gear section 146, an internal splined section 148, an external axial surface 150, and / or a radial surface 152. The external bevel gear section 146 of the axle shaft gear 106 and / or the limited-slip axle shaft gear 108 can mesh with the bevel gears 142 of the bevel gear set 104. The internal splined section 148 can extend axially along a selected length of the limited-slip axle shaft gear 108. The internal splined section 148 can point inwards towards the central axis of the axle shaft gear 106 and / or the limited-slip axle shaft gear 108. The external axial surface 150 can point radially outwards, away from the central axis of the axle shaft gear 106 and / or the limited-slip axle shaft gear 108. The radial surface 152 can extend radially outwards from the external axial surface 150.The radial surface 152 can be arranged axially between the external axial surface 150 and the external bevel gear section 146.

[0042] The locking axle gear 108 can include an external axial surface 154, a radially toothed surface 156, and / or an external axial surface 158. In addition to the external bevel gear section 146, the internal splined section 148, the external axial surface 150, and / or the radial surface 152, the locking axle gear 108 can also include the external axial surface 154, the radially toothed surface 156, and / or the external axial surface 158. The locking axle gear 108 can be considered "locking" if it includes the external axial surface 154, the radially toothed surface 156, and / or the external axial surface 158.

[0043] The external axial surface 154 and / or the external axial surface 158 can point radially outward from the central axis of the locking shaft gear 108. The radial surface 152 can be arranged radially between the external axial surface 150 and the external axial surface 154, coupling them together. The radial surface 152 can also be arranged axially between the external axial surface 150 and the external axial surface 154. The external axial surface 154 can be arranged radially outside the external axial surface 150. The external axial surface 154 can be arranged axially between the radial surface 152 and the radially toothed surface 156, coupling them together. The radially toothed surface 156 can be arranged radially between the external axial surface 154 and the external axial surface 158, coupling them together.The radially toothed surface 156 can also be arranged axially between the external axial surface 154 and the external axial surface 158. The external axial surface 158 can be arranged radially outside the external axial surface 154. The external axial surface 158 can be arranged axially between the radially toothed surface 156 and the external bevel gear section 146, coupling them together. The axial positions can sequentially range from the external axial surface 150, via the radial surface 152, the external axial surface 154, the radially toothed surface 156, the external axial surface 158, to the external bevel gear section 146.

[0044] The external axial surface 150, the external axial surface 154 and / or the external axial surface 158 can be a cylindrical surface that coincides with the central axis of the locking axle gear 108. The radial surface 152 can be an annular surface that coincides with the central axis of the locking axle gear 108.

[0045] The clutch disc 114 and the locking axle gear 108 can be coupled by a rotary joint. For example, the clutch disc 114 and the external axial surface 154 of the locking axle gear 108 can be coupled by the rotary joint. The rotary joint can include two degrees of freedom, with the clutch disc 114 configured to move axially relative to the locking axle gear 108 and to rotate about the central axis. The clutch disc 114 can be arranged radially outside the external axial surface 154 and thus coupled to it.

[0046] The electric limited-slip differential 100 can be configured in unlocked and locked configurations by engaging or disengaging the clutch plate 114 with the locking axle gear 108. For example, the clutch plate 114 can be unlocked and thus locked by the radially toothed surface 156 of the locking axle gear 108. The clutch plate 114 can be unlocked and thus locked by moving axially away from and then axially towards the radially toothed surface 156 of the locking axle gear 108.

[0047] The clutch disc 114 and the locking axle gear 108 can form a dog clutch in the locked configuration. For example, the clutch disc 114 and / or the radially toothed surface 156 of the locking axle gear 108 can form a dog clutch. The clutch disc 114 and / or the radially toothed surface 156 can include drive lugs 160. The drive lugs 160 can also be referred to as drive lug teeth. The clutch disc 114 and / or the radially toothed surface 156 of the locking axle gear 108 can include a corresponding number of drive lugs 160. The drive lugs 160 can be arranged in a polar arrangement around the central axis of the electric locking differential. The drive lugs 160 of the clutch disc 114 and / or the radially toothed surface 156 can engage with each other, thereby locking the clutch disc 114 with the radially toothed surface 156 of the locking axle gear 108.The clutch disc 114 can be axially displaced away from the radially toothed surface 156, thereby unlocking the drive lugs 160 and disengaging the clutch disc 114 from the radially toothed surface 156.

[0048] The retaining ring 110 and / or the return spring 112 can return the clutch disc 114, the actuating pins 116, the thrust bearing 118, the bushing 120, and / or the electromagnet 122 from the locked configuration to the unlocked configuration when the electromagnet 122 is deactivated. The clutch disc 114 can move axially away from the locking axle gear 108 by means of the retaining ring 110 and / or the return spring 112. The retaining ring 110 can be a snap ring or similar. The return spring 112 can be a compression spring. The return spring 112 can, for example, be a wave-shaped compression spring. The retaining ring 110 and / or the return spring 112 can be arranged radially outside the locking axle gear 108 and / or be axially aligned with it. For example, the retaining ring 110 and / or the return spring 112 can be arranged radially outside the external axial surface 158 and / or axially aligned with it.The return spring 112 can be arranged axially between the retaining ring 110 and the clutch disc 114 and radially aligned with them, thus coupling them. The return spring 112 can push the clutch disc 114 away from the retaining ring 110. The return spring 112, which pushes the clutch disc 114 away from the retaining ring 110, can, with an axial translational movement, push the clutch disc 114 away from the radially toothed surface 156 of the locking axle gear 108, thereby unlocking the clutch disc 114 from the locking axle gear 108.

[0049] The electromagnet 122 can move the electrical locking differential 100 from the unlocked configuration to the locked configuration when the electromagnet 122 is activated. The clutch disc 114 can be configured to move axially towards the locking axle gear 108 by means of the actuating pins 116, the thrust bearing 118, the bushing 120, and / or the electromagnet 122. The actuating pins 116, the thrust bearing 118, and / or the bushing 120 can be radially aligned with the clutch disc 114. The actuating pins 116 can be arranged axially between the thrust bearing 118 and the clutch disc 114, radially aligned with it, and coupled to it. The clutch disc 114 can be arranged axially between the actuating pins 116 and the bushing 120, radially aligned with it, and coupled to it. The electromagnet 122 can be arranged radially outside the socket 120, aligned axially with it and fixed to it.The electromagnet 122 can be configured to generate an electromagnetic field.

[0050] The electromagnet 122 can include coils 162 and an iron-containing housing 164. The electromagnet 122 can engage with the coils 162. The coils 162 can be configured to generate the electromagnetic field in response to an electric current flowing through them. The electromagnetic field can axially displace the electromagnet 122 toward the actuating side housing 128. This axial displacement of the electromagnet 122 toward the actuating side housing 128 can cause axial displacement of the clutch disc 114, the actuating pins 116, the thrust bearing 118, the bushing 120, and / or the electromagnet 122 itself. The return spring 112 can counteract this axial displacement.The electromagnetic field can be strong enough to overcome the return spring 112 and thereby move the clutch disc 114 axially from the unlocked to the locked configuration when the electromagnet 122 generates the electromagnetic field. Subsequently, the return spring 112 can return the clutch disc 114 to the unlocked configuration when the electromagnetic field is eliminated after the electromagnet 122 is deactivated.

[0051] The clutch disc 114, the actuating pins 116, the thrust bearing 118, the bushing 120 and / or the electromagnet 122 can be configured to move axially by a specific distance between the unlocked and locked configurations. For example, the clutch disc 114, the actuating pins 116, the thrust bearing 118, the bushing 120 and / or the electromagnet 122 can be configured to move axially between 1 and 3 mm between the unlocked and locked configurations.

[0052] The side housing 124, the inner housing 126, and / or the actuating side housing 128 can be fixed to the final drive gear 102. The side housing 124, the inner housing 126, and / or the actuating side housing 128 can rotate with the final drive gear 102 by being fixed to it. For example, the side housing 124, the inner housing 126, and / or the actuating side housing 128 can be fixed to the flange 136 of the final drive gear 102. The side housing 124 can be fixed to a first side of the flange 136, and the inner housing 126 and / or the actuating side housing 128 can be fixed to a second side of the flange, opposite the first. The inner housing 126 can be fixed between the flange 136 and the actuating side housing 128. The flange 136 can be arranged axially between the side housing 124 and the inner housing 126 and / or the actuating side housing 128.The inner housing 126 can be arranged axially between the actuating side housing 128 and the flange 136.

[0053] The path by which the torque is transmitted from the final drive gear 102 through the bevel gear set 104 to the axle shaft gear 106 and / or the locking axle shaft gear 108 must not pass through the side case 124, the inner case 126, and / or the actuating side case 128 in the unlocked configuration. The torque is not transmitted through the side case 124, the inner case 126, and / or the actuating side case 128 due to the interface between the pins 140 and the recessed sections 138. Therefore, the torque acting on the side case 124, the inner case 126, and / or the actuating side case 128 can be relatively small when the final drive gear 102 receives the torque. Such an arrangement can be advantageous in order to reduce the requirements for the strength of the side housing 124, the inner housing 126 and / or the actuating side housing 128.

[0054] The side housing 124, the inner housing 126, and / or the actuator side housing 128 can include one or more sections. For example, the actuator side housing 128 can include a flanged section 170, an axial section 172, a radial section 174, and / or an axial section 176. In another example, the inner housing 126 can include the flanged section 170 and / or an axial section 172. In yet another example, the actuator side housing 128 can include the flanged section 170 and / or the axial section 176.

[0055] The flange section 170 of the side housing 124, the inner housing 126, and / or the actuating side housing 128 can be coupled to the flange 136 of the final drive gear 102. For example, the flange section 170 of the side housing 124 and the inner housing 126 can be radially aligned with and abutting the opposite axial sides of the flange 136 of the final drive gear 102. Similarly, the flange section 170 of the actuating side housing 128 and the flange 136 of the final drive gear 102 can be radially aligned with and abutting the opposite axial sides of the flange section 170 of the inner housing 126.

[0056] The axial section 172 of the inner housing 126 and / or the actuating side housing 128 can be arranged radially inside the flange section 170 of the inner housing 126 or the actuating side housing 128, respectively, and extend axially from it. The axial section 172 of the inner housing 126 can be aligned axially with the axial section 172 of the actuating side housing 128, arranged radially inward to it, and abutting it.

[0057] The radial section 174 of the actuating side housing 128 can extend radially inwards from the axial section 172 of the actuating side housing 128. The flange section 170 and the radial section 174 of the actuating side housing 128 can be arranged at opposite axial ends of the axial section 172 of the actuating side housing 128.

[0058] The axial section 176 of the actuating side housing 128 can be arranged radially inside the radial section 174 of the actuating side housing 128 and extend axially from it. The axial section 172 and the axial section 176 of the inner housing 126 can extend in opposite axial directions from the radial section 174 of the actuating side housing 128.

[0059] The axial section 176 of the side housing 124 can be radially aligned with the axial section 176 of the actuating side housing 128 and axially offset thereto.

[0060] The final drive gear 102, the side housing 124, the inner housing 126, and / or the actuating side housing 128 can accommodate one or more components of the electric limited-slip differential 100. For example, the final drive gear 102, the side housing 124, the inner housing 126, and / or the actuating side housing 128 can accommodate the bevel gear set 104, the axle shaft gear 106, the limited-slip axle shaft gear 108, the retaining ring 110, the return spring 112, the clutch disc 114, and / or the actuating pins 116. The bevel gears 142 of the bevel gear set 104 and / or the axle shaft gear 106 can be arranged radially inside the side housing 124 and thus be axially aligned. The bevel gears 142 of the bevel gear set 104, the locking axle shaft gear 108, the retaining ring 110, the return spring 112 and / or the clutch disc 114 can be arranged radially within the inner housing 126 and / or the actuating side housing 128 and aligned axially with it.The side housing 124 and the inner housing 126 can axially hold the pins 140 in the recessed sections 138.

[0061] The axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 can be coupled to the side housing 124 or the actuating side housing 128 via a pivot joint. The axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 can be configured to rotate relative to the side housing 124 or the actuating side housing 128 via the pivot joint in the unlocked configuration. The external axial surface 150 of the axle shaft sprocket 106 and / or the locking axle shaft sprocket 108 can bear against the side housing 124 or the actuating side housing 128. For example, the external axial surface 150 can bear against the side housing 124 and the actuating side housing 128 via a wear bushing. The wear bushing can be located between the external axial surface 150 and the radial section 174 of the actuating side housing 128. The radial surface 152 of the axle shaft gear 106 and / or the locking axle shaft gear 108 can be separated from the side housing 124 by a clearance fit.The inner housing 126 is separated. The clearance fit can exist between the axle shaft gear 106 and an inner diameter of the axial section 176 of the side housing 124. The clearance fit can exist between the locking axle shaft gear 108 and an inner diameter of the axial section 176 of the actuating side housing 128. The wear bushing and / or the clearance fit can form the pivot joint.

[0062] The clutch disc 114 can be configured to displace axially relative to the final drive gear 102, the side housing 124, the inner housing 126, and / or the actuating side housing 128. The clutch disc 114 and the inner housing 126 can be coupled to each other via a splined connection 166. The splined connection 166 of the clutch disc 114 can be an external splined connection pointing outwards away from the central axis of the clutch disc 114. The splined connection 166 of the inner housing 126 can be an internal splined connection pointing inwards towards the central axis of the inner housing 126. The splined connection 166 of the inner housing 126 can be formed on an inner diameter of the axial section 172 of the inner housing 126. The splined connection 166 of the clutch disc 114 and the inner housing 126 can engage with each other. The splined connection 166 can couple the clutch disc 114 and the inner housing 126 in a sliding manner.For example, the clutch disc 114 and the inner housing 126 can be coupled by a sliding joint with one degree of freedom, whereby the clutch disc 114 can move axially relative to the inner housing 126, but does not undergo any other form of translation or rotation relative to the inner housing 126.

[0063] The clutch plate 114 can lock the differential gear 108 with the inner housing 126 in the locked position. For example, the splined connection 166 can lock the differential gear 108 with the inner housing 126 when the clutch plate 114 is coupled to the differential gear 108. Torque can be transmitted from the drive lugs 160 of the differential gear 108 to the inner housing 126 via the splined connection 166. The inner housing 126 and / or the actuating side housing 128 can bear some of the torque when the clutch plate 114 is coupled to the differential gear 108. For example, adding the inner housing 126 can reinforce the actuating side housing 128 for transmitting torque from the differential gear 108 to the inner housing 126. By locking the locking axle shaft wheel 108 with the inner housing 126, the final drive gear 102 and / or the bevel gear set 104 can also be locked with the locking axle shaft wheel 108.By locking the locking axle shaft gear 108 with the locking axle shaft gear 108, the bevel gear set 104, the axle shaft gear 106, and the locking axle shaft gear 108 can be locked together, thus preventing differential rotation. Although the electric locking differential is described with the inner housing 126, this is not intended as a limitation of the present disclosure. The functionality of the inner housing 126 can be replaced by the actuating side housing 128. For example, the actuating side housing 128 can include the splined connection 166. However, the inner housing 126 can be advantageous for improving the strength of the electric locking differential 100.

[0064] The retaining ring 110 can be fixed to the inner housing 126. For example, the retaining ring 110 can be fixed to the inner diameter of the axial section 172 of the inner housing 126. Although the retaining ring 110 is described as being fixed to the inner housing 126, this is not intended as a limitation of the present disclosure. It is further provided that the retaining ring 110 can be fixed to the external axial surface 158 of the locking shaft gear 108.

[0065] The actuating pins 116 can be configured to move through the actuating side housing 128 in a translational motion. For example, the actuating pins 116 can move through the radial section 174 of the actuating side housing 128 in a translational motion. The actuating pins 116 and the actuating side housing 128 can be coupled by a sliding joint. The sliding joint can include one degree of freedom, with the actuating pins 116 configured to move axially relative to the actuating side housing 128. The actuating pins 116 can rotate along with the rotation of the actuating side housing 128. The sliding joint between the actuating pins 116 and the actuating side housing 128 can extend through the radial section 174 of the actuating side housing 128.For example, the radial section 174 can define wedge bores through which the actuating pins 116 can move.

[0066] The bushing 120 and the electromagnet 122 must not rotate together with the final drive gear 102. The bushing 120 and the actuating side housing 128 can be coupled by a rotary-slide joint. The rotary-slide joint can include two degrees of freedom, with the bushing 120 configured to displace axially relative to the actuating side housing 128 and to rotate about its central axis relative to the actuating side housing 128. The rotary-slide joint can extend along an inner diameter of the bushing 120 and an outer diameter of the axial section 176 of the actuating side housing 128. For example, the bushing 120 can be both a rotating and an axial bushing. The actuating pins 116 can interact with the thrust bearing 118 so that a force can be exerted on the actuating pins 116 when the final drive gear 102 rotates and the electromagnet 122 remains stationary.The thrust bearing 118 can couple the axial displacement of the bushing 120 and the electromagnet 122 with the actuating pins 116 and the clutch disc 114, without connecting the rotation of the final drive gear 102 through the actuating side housing 128 and the actuating pins 116 with the bushing 120 and the electromagnet 122.

[0067] The side housing 124, the inner housing 126, and / or the actuator side housing 128 can be made of a selected material. For example, the side housing 124, the inner housing 126, and / or the actuator side housing 128 can be made of a ferrous material (e.g., iron-steel). The electromagnet 122 can cause the electromagnetic field to couple through the ferrous housing 164 to the actuator side housing 128 when the electromagnet 122 is activated. The ferrous housing 164 can be directly coupled to the actuator side housing 128.

[0068] The ferrous housing 164 must not touch the actuating side housing 128 when the electrical locking differential 100 is in the unlocked and / or locked configuration. The thrust bearing 118 and the bushing 120 may maintain a gap between the ferrous housing 164 and the actuating side housing 128 in the locked configuration.

[0069] The ferrous housing 164 and the actuator side housing 128 may include a chamfered edge 168. The electromagnetic field can couple from the ferrous housing 164 to the actuator side housing 128 via the chamfered edge 168. The chamfered edge 168 may form a conical magnetic pole interface between the chamfered edge 168 and the actuator side housing 128. The chamfered edge 168 of the ferrous housing 164 may point inwards towards the central axis of the electromagnet 122. The chamfered edge 168 of the actuator side housing 128 may point outwards away from the central axis of the actuator side housing 128. The chamfered edge 168 of the actuator side housing 128 may be formed between the axial section 172 and the radial section 174 of the actuator side housing 128. The actuator side housing 128 can be formed with a chamfered edge 168.For example, the actuator side housing 128 can be formed with the chamfered edge 168 during stamping, or the chamfered edge 168 can be machined after stamping.

[0070] The ferrous housing 164 can be U-shaped and have an open section that points axially to the actuating side housing 128. For example, the open section can point axially to the radial section 174 of the actuating side housing 128. The chamfered edge 168 can be defined at one apex of the U-profile. The coils 162 can be arranged in the center of the U-shape.

[0071] Bearing 130 and bearing 131 can be arranged at opposite axial ends of the electric locking differential 100. Bearing 130 and bearing 131 can each be coupled to the side housing 124 and the actuating side housing 128, respectively. For example, bearing 130 and bearing 131 can be coupled to the outer diameter of the axial section 176 of side housing 124 and the axial section 176 of the actuating side housing 128. Bearing 131 can be radially aligned with the bushing 120. Side housing 124 and actuating side housing 128 can support the electric locking differential 100 via bearing 130 and bearing 131. The final drive gear 102 can be supported by the bearing 130 and the bearing 131 via the side housing 124 and the actuating side housing 128.The side housing 124 and the housing on the actuating side 128 can support the final drive gear 102 in such a way that the final drive gear 102 does not deflect when the final drive gear 102 absorbs a large torque.

[0072] Bearing 130 and bearing 131 can be any type of radial bearing. For example, bearing 130 and bearing 131 can be a cylindrical bearing, a tapered roller bearing, a needle roller bearing, a ball bearing, a plain bearing (e.g., a bushing), or something similar. As shown, bearing 130 and bearing 131 are tapered roller bearings, but this is not intended as a limitation.

[0073] The final drive gear 102, the side housing 124, the inner housing 126, and / or the actuating side housing 128 can be fixed using any suitable technique, such as with the fasteners 132, a weld, or the like. For example, the final drive gear 102, the side housing 124, the inner housing 126, and / or the actuating side housing 128 can be fixed using the fasteners 132. The fasteners 132 can be arranged in bores through the final drive gear 102, the side housing 124, the inner housing 126, and / or the actuating side housing 128. The fasteners 132 can clamp the final drive gear 102, the side housing 124, the inner housing 126, and / or the actuating side housing 128 together. Although it is described that the electrical locking differential 100 includes the fastening elements 132, this is not intended as a limitation of the present disclosure.The final drive gear 102, the side housing 124, the inner housing 126 and / or the actuating side housing 128 can be fixed in place by means of a weld or similar. The weld can be an edge weld around an outer diameter of the flange section 170 of the side housing 124, the inner housing 126 and / or the actuating side housing 128.

[0074] The side housing 124, the inner housing 126, and / or the actuator side housing 128 can be stamped. For example, the side housing 124, the inner housing 126, and / or the actuator side housing 128 can be cold-formed. The electrical differential configuration can allow the side housing 124, the inner housing 126, and / or the actuator side housing 128 to be stamped while maintaining the functionality of the unlocked and locked configurations and meeting a selected strength requirement for the housings. The inner housing 126 and the actuator side housing 128 can also be formed as an integral unit. However, separating the inner housing 126 and the outer housing of the actuator side housing 128 can allow the inner housing 126 and the actuator side housing 128 to be stamped.

[0075] The socket 120, the electromagnet 122, and the ring-shaped position sensor 178 can be fixed in place. The socket 120, the electromagnet 122, and the ring-shaped position sensor 178 can rotate together and / or move axially.

[0076] The bushing 120 can comprise an axial section 182 and a radial section 184. The radial section 184 can extend radially outward from an axial end of the axial section 182. The radial section 184 of the bushing 120 can be fixed to the electromagnet 122, coupled to the thrust bearing 118, and / or fixed to the annular position sensor 178. The radial section 184 of the bushing 120 can be fixed to the ferrous housing 164 of the annular position sensor 178. The axial section 182 of the bushing 120 can form the rotary joint with the actuating side housing 128 and / or be fixed to the annular position sensor 178.

[0077] The ring-shaped position sensor 178 can include sensor electronics 186 and / or a sensor housing 188. The sensor housing 188 can be ring-shaped. The sensor housing 188 can contain the sensor electronics 186.

[0078] The sensor housing 188 can be fixed to the socket 120 and / or the electromagnet 122. The sensor housing 188 can be fixed to the axial section 182 and / or the radial section 184 of the socket 120. The sensor housing 188 can be fixed to the ferrous housing 164 of the electromagnet 122.

[0079] The sensor electronics 186 can be housed in the sensor housing 188. The sensor electronics 186 can include a circuit board, position sensors, a connector, and similar components. The shape of the sensor electronics 186 can vary depending on its design. The sensor electronics 186 can include one or more position sensors. The position sensors can be arranged circumferentially around the ring-shaped position sensor 178. The sensor electronics 186 can determine the average of the position measurements from several position sensors.

[0080] The sensor electronics 186 can incorporate any suitable type of position sensor. For example, the sensor electronics 186 can include inductive position sensors (e.g., an inductive linear position sensor), magnetic position sensors, or similar devices.

[0081] Due to the radial position of the ring-shaped position sensor 178 within the electromagnet 122 and the electromagnetic fields generated by the electromagnet 122, the inductive position sensors can be more accurate than magnetic position sensors. The inductive position sensors must not detect the electromagnetic field generated by the electromagnet 122 as noise.

[0082] The annular position sensor 178 can be axially aligned with the electromagnet 122, arranged radially inside it, and fixed to it. The annular position sensor 178 can be axially aligned with the axial section 182 of the bushing 120 and the electromagnet 122, arranged radially between them, and fixed to it. The annular position sensor 178 can be axially offset from the radial section 184 of the bushing 120, radially aligned with it, and fixed to it. The axial section 182 and / or the radial section 184 can be axially aligned with the electromagnet 122 and arranged radially inside it. The radial section 184 can be arranged axially between the annular position sensor 178 and the thrust bearing 118. The bushing 120 and the electromagnet 122 can define a cavity between them. For example, the axial section 182 and the radial section 184 of the bushing 120 can define a cavity between the electromagnet 122.The annular position sensor 178 can be fixed to the socket 120 and the electromagnet 122 in the cavity. The geometry of the socket 120 allows the annular position sensor 178 to be fixed radially between the socket 120 and the electromagnet 122. The position of the annular position sensor 178 relative to the socket 120 and the electromagnet 122 can be advantageous for reducing the size of the electrical locking differential 100. For example, the axial alignment of the annular position sensor 178 with the socket 120 and the electromagnet 122, together with the radial arrangement of the annular position sensor 178 between the socket 120 and the electromagnet 122, can provide a compact assembly.

[0083] The clutch disc 114, the actuating pins 116, the thrust bearing 118, the bushing 120, the electromagnet 122, and the annular position sensor 178 can move axially together. For example, the clutch disc 114, the actuating pins 116, the thrust bearing 118, the bushing 120, the electromagnet 122, and the annular position sensor 178 can move axially between the unlocked and locked configurations. The clutch disc 114 and the actuating pins 116 can rotate together with the final drive gear 102, the inner housing 126, and / or the actuating side housing 128, while the bushing 120, the electromagnet 122, and the annular position sensor 178 remain stationary due to the thrust bearing 118.

[0084] The axial position of the clutch disc 114 relative to the annular position sensor 178 can be fixed. For example, the axial position of the clutch disc 114 relative to the annular position sensor 178 can be fixed by allowing the clutch disc 114, the actuating pins 116, the thrust bearing 118, the bushing 120, the electromagnet 122, and the annular position sensor 178 to move axially together. A relative axial position of the annular position sensor 178 can indicate a relative axial position of the clutch disc 114 by fixing the axial position of the clutch disc 114 relative to the annular position sensor 178.

[0085] The target ring 180 can be fixed to the actuator side housing 128. For example, the target ring 180 can be fixed to an outer diameter of the axial section 176 of the actuator side housing 128. The target ring 180 can be fixed to the actuator side housing 128 by a snap ring, a weld, or similar means. The target ring 180 can rotate together with the actuator side housing 128. The target ring 180 can be radially aligned with the annular position sensor 178 and axially offset from it. The target ring 180 can be arranged axially between the bearing 131 and the annular position sensor 178.

[0086] The 180mm target ring can be made of a selected metal. For example, the 180mm target ring can be made of a non-ferrous metal such as aluminum or stainless non-ferrous steel.

[0087] The axial position of the target ring 180 relative to the locking axle gear 108 can be fixed. This can be achieved by fixing the target ring 180 to the actuating side housing 128 and coupling the locking axle gear 108 and the actuating side housing 128 via the pivot joint. A relative axial position of the target ring 180 can indicate a relative axial position of the radially toothed surface 156 by fixing the axial position of the target ring 180 relative to the radially toothed surface 156.

[0088] The target ring 180 can have a ring-shaped form without a pattern. The target ring 180 can provide a uniform surface from which the ring-shaped position sensor 178 can detect a relative axial position.

[0089] The annular position sensor 178 can detect the relative axial position from the annular position sensor 178 to the target ring 180. The relative axial position from the annular position sensor 178 to the target ring 180 can indicate the relative axial position from the clutch disc 114 to the radially toothed surface 156 of the locking axle gear 108. For example, the relative axial position from the annular position sensor 178 to the target ring 180 can indicate the relative axial position from the clutch disc 114 to the radially toothed surface 156 of the locking axle gear 108 because the axial position from the annular position sensor 178 to the clutch disc 114 is fixed, and the axial position from the target ring 180 to the radially toothed surface 156 of the locking axle gear 108 is also fixed.

[0090] The relative axial position of the annular position sensor 178 to the target ring 180 can also indicate whether the electric locking differential 100 is in the unlocked or locked configuration. For example, the relative axial position of the clutch disc 114 to the radially toothed surface 156 of the locking axle gear 108 can indicate that the electric locking differential 100 is in the unlocked configuration if the relative axial position shows that the clutch disc 114 is not adjacent to the radially toothed surface 156 and therefore is not meshing with it, and that it is in the locked configuration if the clutch disc 114 is adjacent to the radially toothed surface 156 and is therefore meshing with it.For example, the relative axial position between the annular position sensor 178 and the target ring 180 can indicate that the electrical locking differential 100 is configured to be in the unlocked configuration or in the locked configuration.

[0091] The relative axial position between the annular position sensor 178 and the target ring 180 can be used as feedback for controlling the electric locking differential 100. For example, the relative axial position of the annular position sensor 178 to the target ring 180 can be used as feedback for controlling the torque to the final drive gear 102 and / or for controlling the electromagnet 122. The torque acting on the final drive gear 102 can be controlled depending on whether the electric locking differential 100 is in the unlocked or locked configuration. Likewise, the electromagnet 122 can be controlled to ensure that the electric locking differential 100 remains in the unlocked or locked configuration.

[0092] Fig.Figure 2 represents a powertrain 200 according to one or more embodiments of the present disclosure. The powertrain 200 can be part of an electric axle (e-axle), a hybrid transmission, an internal combustion powertrain, or the like. The powertrain 200 can be used in a vehicle, e.g., in a passenger car, a truck, an off-road vehicle, or a crossover vehicle. The powertrain 200 can, for example, be a powertrain of a front-wheel-drive vehicle.

[0093] The drivetrain 200 can include the electric locking differential 100, a pair of axles 202, a pair of driven wheels 204, a motor 206, and / or a transmission 208. The motor 206 can be mounted off-center to the central axle of the electric locking differential 100. The motor 206 can be an electric motor, an internal combustion engine, a hybrid motor, or the like. The motor 206 can be coupled to the final drive gear 102 of the electric locking differential. For example, the motor 206 can be coupled to the final drive gear 102 via the transmission 208. The transmission 208 can couple the torque from the motor 206 to the final drive gear 102. The transmission 208 can downshift the torque from the motor 206 to the final drive gear 102. The gearbox 208 can include one or more gear engagements for downshifting the motor 206 to the final drive gear 102.The gearbox 208 can include any number of gear engagements to achieve a desired gear ratio between the motor 206 and the final drive gear 102.

[0094] The axes 202 can be axially coupled to the electrical locking differential 100.

[0095] For example, the axles 202 can be coupled to the internal splined connection 148 of the axle shaft gear 106 or the locking axle shaft gear 108. The electric locking differential 100 can transmit the torque from the final drive gear 102 to the axles 202. The driven wheels 204 can be coupled to the respective axles 202. The axles 202 can transmit the torque to the driven wheels 204.

[0096] The electric locking differential 100 can provide differential of the axles 202 and / or the driven wheels 204 when the electric locking differential 100 is in the unlocked configuration, and can lock the rotation of the axles 202 and / or the driven wheels 204 together when the electric locking differential 100 is in the locked configuration.

[0097] The bearing 130 and the bearing 131 can support the electric locking differential 100 on a vehicle frame of the powertrain 200.

[0098] The term "axial" and related terms and phrases refer to a direction along the axis of a rotor shaft configured to rotate around the axis during operation of the device described herein. The term "radial" and related terms and phrases refer to the axis of the aforementioned rotor shaft. For example, "radially outward" means farther from the axis, while "radially inward" means a position closer to the axis. The term "circumferential" and related terms and phrases refer to the axis of the rotor shaft.

[0099] A person skilled in the art will recognize that the components, devices, objects, and accompanying discussion described here are used as examples for conceptual clarity and that various configuration changes are being considered. Consequently, the specific examples presented here and the accompanying discussion are to be understood as representative of their more general classes. In general, the use of a particular example is intended to be representative of its class, and the omission of certain components, processes, devices, and objects is not intended as a limitation.

[0100] Directional terms such as "top," "bottom," "over," "below," "above," "upwards," "downwards," "below," and "downwards" serve to describe relative positions and not to designate an absolute frame of reference. Various modifications of the described embodiments will be obvious to those skilled in the art, and the general principles defined here can also be applied to other embodiments.

[0101] Regarding the use of terms in the plural and / or singular, experts may translate the plural into the singular and / or the singular into the plural as appropriate to the context and / or application. The various singular / plural permutations are not explicitly listed here for the sake of clarity.

[0102] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the description are descriptive and not limiting, and it is understood that various modifications can be made without deviating from the fundamental idea and scope of protection of the disclosure. As previously described, the features of different embodiments can be combined to form further embodiments of the disclosure that may not be expressly described or illustrated.While various embodiments could have been described as advantageous or preferred over other embodiments or implementations in the prior art with respect to one or more desired properties, those skilled in the art recognize that a compromise can be made with respect to one or more features or properties in order to achieve desired overall system attributes, which depend on the specific application and implementation. Therefore, if embodiments are described as less desirable than other embodiments or implementations in the prior art with respect to one or more properties, these embodiments are not outside the scope of protection of the disclosure and may be desirable in certain applications. List of reference symbols 100 Electric locking differential 102 Final drive gear 104 Bevel gear set 106 Axle shaft wheel 108 Locking axle gear 110 retaining ring 112 Return spring 114 Clutch disc 116 actuating pins 118 thrust bearings 120 socket 122 Electromagnet 124 side cases 126 inner housings 128 Actuator side housings 130 storage 131 warehouses 132 fasteners 134 External helical gear 136 flange 138 recessed sections 140 pens 142 bevel gears 144 Middle Section 146 External bevel gear section 148 Internal splined connection 150 External axial surface 152 Radial surface 154 External axial surface 156 Radially toothed surface 158 External axial surface 160 carriers 162 coils 164 Iron-containing casing 166 Splined connection 168 Beveled edge 170 flange section 172 Axial section 174 Radial section 176 Axial section 178 Ring-shaped position sensor 180 target ring 182 Axial section 184 Radial section 186 Sensor electronics 188 Sensor housings 200 Powertrain 202 axles 204 Driven Wheels 206 engine 208 gearbox

Claims

[1] Electrical locking differential comprising: a final drive gear, wherein the final drive gear comprises an external helical gear and a flange, the flange being arranged radially inside the external helical gear and axially aligned with it; an actuating side housing, wherein the actuating side housing is fixed to the flange, wherein the final drive gear and the actuating side housing are configured to rotate together about a central axis; a targeting ring, wherein the targeting ring is fixed to the actuating side housing; a bushing, wherein the bushing and the actuating side housing are coupled by a rotary sliding joint; and an annular position sensor, wherein the socket and the annular position sensor are fixed, wherein the annular position sensor is configured such that that it detects a relative axial position between the annular position sensor and the target ring, wherein the relative axial position between the annular position sensor and the target ring indicates that the electrical locking differential is configured in an unlocked configuration or a locked configuration. [2] Electrical locking differential according to claim 1, wherein the ring-shaped position sensor comprises one or more inductive position sensors. [3] Electric locking differential according to claim 1, wherein the bushing comprises an axial section and a radial section, wherein the radial section extends radially outwards from the axial section, wherein the axial section forms the rotary sliding joint with the actuating side housing, wherein the annular position sensor is axially aligned with the axial section of the bushing and is arranged radially outside to it, wherein the annular position sensor is radially aligned with the radial section of the bushing. [4] Electric locking differential according to claim 1, comprising an electromagnet, wherein the actuating side housing is made of an iron-containing material, wherein the electromagnet configures the electric locking differential such that it changes from the unlocked configuration to the locked configuration when the electromagnet is activated, wherein the bushing, the electromagnet and the annular position sensor are fixed, wherein the electromagnet, the bushing and the annular position sensor do not rotate together with the final drive gear and the actuating side housing. [5] Electrical locking differential according to claim 4, wherein the electromagnet is arranged radially outside the bushing, axially aligned with it and fixed thereto. [6] Electric locking differential according to claim 1, comprising a bearing coupled to the actuating side housing, wherein the bearing is coupled to the actuating side housing, wherein the bearing is radially aligned with the bushing, wherein the target ring is arranged axially between the bearing and the annular position sensor. [7] Electrical locking differential according to claim 1, comprising: a locking axle gear, wherein an axial position of the target ring relative to the locking axle gear is defined; and a clutch disc, wherein the clutch disc and the locking axle gear in the locked configuration form a claw clutch, wherein an axial position of the clutch disc relative to the annular position sensor is defined. [8] Electrical locking differential according to claim 7, comprising: a bevel gear set, wherein the bevel gear set comprises a plurality of bevel gears, wherein the plurality of bevel gears is fixed to the flange, wherein the final drive gear and the bevel gear set are configured to rotate together about the central axis, wherein the plurality of bevel gears is orthogonal to the central axis and rotates about it via an orbital motion; and an axle shaft gear, wherein the axle shaft gear and the locking axle shaft gear are coupled to the plurality of bevel gears, the bevel gear set being arranged axially between the axle shaft gear and the locking axle shaft gear, wherein the axle shaft gear and the locking axle shaft gear rotate independently of each other in the unlocked configuration, and wherein the axle shaft gear and the locking axle shaft gear rotate together in the locked configuration. [9] Electric locking differential according to claim 8, wherein the flange defines a plurality of recessed sections, wherein the bevel gear set comprises a plurality of pins, wherein the plurality of pins and the plurality of bevel gears are fixed to one another, wherein the plurality of pins is arranged within and abuts the plurality of recessed sections, wherein the plurality of pins and the plurality of bevel gears are orthogonal to the central axis and rotate about it via an orbital motion. [10] Electric locking differential according to claim 7, comprising a return spring, wherein the return spring is configured to return the clutch disc from the locked configuration to the unlocked configuration. [11] Electric locking differential according to claim 10, wherein the locking axle gear, the return spring and the clutch disc are arranged radially inside the actuating side housing and are axially aligned therewith. [12] Electric locking differential according to claim 10, comprising a thrust bearing and a plurality of actuating pins, wherein the plurality of actuating pins rotates together with the actuating side housing, wherein the plurality of actuating pins are arranged axially between the thrust bearing and the coupling plate, are radially aligned and coupled thereto, wherein the thrust bearing is arranged axially between the bushing and the plurality of actuating pins, are radially aligned and coupled thereto. [13] Electric locking differential according to claim 12, wherein the thrust bearing is coupled to a radial section of the bushing. [14] Electric locking differential according to claim 12, wherein the thrust bearing couples an axial translational movement between the bushing and the plurality of actuating pins without coupling the rotation of the final drive gear through the actuating side housing and the plurality of actuating pins to the bushing. [15] Electric locking differential according to claim 12, wherein the plurality of actuating pins is configured to move through a radial section of the actuating side housing. [16] Electric locking differential according to claim 10, comprising an inner housing, wherein the inner housing is fixed between the flange and the actuating side housing, wherein the coupling plate and the inner housing are coupled by a splined connection. [17] Electric locking differential according to claim 16, comprising a retaining ring, wherein the return spring is arranged axially between the retaining ring and the clutch disc, is radially aligned and coupled to it, wherein the retaining ring is fixed to the inner housing. [18] Electric locking differential according to claim 16, wherein the flange, the inner housing and the actuating side housing are fixed together by a plurality of fastening elements or a weld. [19] Powertrain, comprising: an electric locking differential, comprising: a final drive gear, wherein the final drive gear comprises an external helical gear and a flange, the flange being arranged radially inside the external helical gear and axially aligned with it; an actuating side housing, wherein the actuating side housing is fixed to the flange, wherein the final drive gear and the actuating side housing are configured to rotate together about a central axis; a targeting ring, wherein the targeting ring is fixed to the actuating side housing; a bushing, wherein the bushing and the actuating side housing are coupled by a rotary sliding joint; and an annular position sensor, wherein the socket and the annular position sensor are fixed, wherein the annular position sensor is configured such that that it detects a relative axial position between the annular position sensor and the target ring, wherein the relative axial position between the annular position sensor and the target ring indicates that the electrical locking differential is configured in an unlocked configuration or a locked configuration; an engine; and a gearbox, whereby the gearbox couples the torque from the motor to the final drive gear. [20] Powertrain according to claim 19, comprising: a pair of axles, wherein the electric locking differential comprises an axle shaft gear and a locking axle shaft gear, the pair of axles being coupled by an internal spline of the axle shaft gear and the locking axle shaft gear; and a pair of driven wheels coupled to the pair of axles, wherein the axle shaft wheel, the locking axle shaft wheel, the pair of axles and the pair of driven wheels are configured to rotate about the central axis.

Images