Differential fixing device

Abstract

A differential system is provided that includes a housing defining an internal cavity. The housing can have a bore communicating with the internal cavity. A pair of pinion gears can be disposed within the internal cavity and rotatably coupled to the housing. First and second side gears disposed within the internal cavity mesh with the pinion gears and are rotatably coupled to the housing. A moving member is configured to rotate with the housing and move between an engaged position and a disengaged position. The housing can be drivingly coupled to the first side gear when the moving member is in the engaged position. An electromagnetic actuation coil is disposed so as not to rotate with the housing and is configured to generate a magnetic field to move the moving member from the disengaged position to the engaged position.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 63 / 380,050, filed October 18, 2022, the entire contents of which are incorporated by reference in their entirety for all purposes.

[0002] This application relates to a locking differential, and more particularly to a locking differential with improved efficiency that has general applicability in many products and industries, including vehicles, robotics, and manufacturing. [Background technology]

[0003] In the context of a vehicle, a locking differential ("locker") can lock all of the vehicle's axles and provide 100% of the available torque to the wheels with traction. Thus, when traction is required, all of the axles can be mechanically locked, allowing the wheels to rotate at the same speed. However, during a turn, the locking differential must act like an open differential to allow the wheels to rotate at different speeds. Summary of the Invention

[0004] In some aspects, the technology described herein relates to a differential system including a housing defining an internal cavity; a pair of pinion gears disposed within the internal cavity and rotatably coupled to the housing; first and second side gears disposed within the internal cavity in meshing engagement with the pinion gears and rotatably coupled to the housing; a moving member configured to rotate with the housing and move between an engaged position and a disengaged position, wherein the housing is drivingly coupled to the first side gear when the moving member is in the engaged position; and an electromagnetic actuation coil disposed not to rotate with the housing and configured to generate a magnetic field to move the moving member from the disengaged position to the engaged position.

[0005] In some aspects, the technology described herein relates to a differential system in which a moving member comprises a base plate, a first wall, and a second wall.

[0006] In some aspects, the technology described herein relates to a differential system in which the first wall is higher than the second wall.

[0007] In some aspects, the technology described herein relates to a differential system in which the electromagnetic actuation coil does not contact the moving members.

[0008] In some aspects, the technology described herein relates to a differential system in which the electromagnetic actuation coil does not further contact the housing.

[0009] In some aspects, the technology described herein relates to a differential system in which a moving member is separated from an electromagnetic actuation coil by a gap when the moving member is in an engaged and disengaged position.

[0010] In some aspects, the technology described herein relates to a differential system in which the gap is between 0.1 mm and 2 mm when the moving members are in an engaged position.

[0011] In some aspects, the technology described herein relates to a differential system in which the gap is between 3 mm and 7.5 mm when the moving members are in a disengaged position.

[0012] In some aspects, the technology described herein relates to a differential locking system including a plurality of rotating components including a housing defining an internal cavity, a first side gear and a second side gear disposed within the internal cavity, and a moving member that moves between a differential locked position and a differential unlocked position; and a plurality of non-rotating components including an electromagnetic actuating component that does not contact the plurality of rotating components, the electromagnetic actuating component interacting with the moving member to move the moving member between the differential locked position and the differential unlocked position, wherein the first side gear is locked relative to the second side gear when the moving member is in the differential locked position.

[0013] In some aspects, the technology described herein relates to a differential locking device system, where the electromagnetic actuating component includes a first actuating surface, the moving member includes a first moving member surface opposing the first actuating surface, and a gap exists between the first moving member surface and the first actuating surface.

[0014] In some aspects, the technology described herein relates to a differential locking system in which the gap between the electromagnetic actuating component and the moving member is between 6 and 4 mm in a differential unlocked position, and the gap between the electromagnetic actuating component and the moving member is between 2 and 0.1 mm in a differential locked position.

[0015] In some aspects, the technology described herein relates to a differential locking system in which a first side gear is coupled to a first drive shaft and a second side gear is coupled to a second drive shaft.

[0016] In some aspects, the technology described herein relates to a differential locking system, wherein the plurality of rotating components further includes a cam ring coupled to the moving member, the cam ring directly engaging the first side gear when the moving member is in a differential locked position.

[0017] In some aspects, the technology described herein relates to a differential locking device system in which the moving members are made from a ferromagnetic metal.

[0018] In some aspects, the technology described herein relates to a differential locking system including: a housing defining an internal cavity, the housing having a rotational axis; first and second gears disposed within the internal cavity and rotatable about the rotational axis; a moving member configured to rotate with the housing and move in a direction parallel to the rotational axis; and an attraction element configured to move the moving member, wherein the attraction element does not contact the moving member.

[0019] In some aspects, the technology described herein relates to a differential locking system in which the suction element does not contact the housing, the first gear, or the second gear in both the differential locked and the differential unlocked states.

[0020] In some aspects, the technology described herein relates to a differential fixation device system in which a moving member includes a first wall configured to interact with a suction element.

[0021] In some aspects, the technology described herein relates to a differential fixation device system, wherein the moving member further includes a second wall configured to interact with a suction element.

[0022] In some aspects, the technology described herein relates to a differential locking device system in which the first wall is higher than the second wall.

[0023] In some aspects, the technology described herein relates to a differential locking system in which the first wall and the second wall at least partially surround the suction element when the differential is in a locked state. [Brief explanation of the drawings]

[0024] The present invention will be described with reference to the accompanying drawings, in which like reference numerals refer to like elements and in which:

[0025] [Figure 1] FIG. 1 is a diagram of a differential having a differential in-drive unit according to an aspect of the present disclosure.

[0026] [Figure 2] FIG. 2 is another view of the drive unit in the differential of FIG. 1.

[0027] [Figure 3] FIG. 2 is another view of the drive unit in the differential of FIG. 1.

[0028] [Figure 4A] 1 is a more detailed view of the drive unit in the differential, and in particular a portion of the rotation lock assembly of the drive unit in the differential.

[0029] [Figure 4B] FIG. 4B is another view of the drive unit in the differential of FIG. 4A.

[0030] [Figure 5] FIG. 10 illustrates an in-differential drive unit positioned within a differential housing in an unlocked state.

[0031] [Figure 6A] 1 illustrates one embodiment of a drive unit in a differential in a locked state.

[0032] [Figure 6B] 10 shows an alternative embodiment of a drive unit in a differential in a locked state.

[0033] [Figure 7A] FIG. 1 is a diagram of an electromagnetic actuation coil.

[0034] [Figure 7B]7B is another view of the electromagnetic actuation coil of FIG. 7A showing the integrated connector.

[0035] [Figure 8] FIG. 1 is a diagram of an electromagnetic actuation coil.

[0036] [Figure 8A] 1 shows a portion of an electromagnetic actuation coil.

[0037] [Figure 8B] A portion of the electromagnetic actuation coil is shown, specifically the sensor body and the PWM controller housing.

[0038] [Figure 8C] A portion of the electromagnetic actuation coil is shown, specifically the integral connector.

[0039] [Figure 9A] 1 shows the solenoid coil housing of the electromagnetic actuation coil.

[0040] [Figure 9B] The solenoid coil housing and tabs are shown.

[0041] [Figure 10] 1 shows a solenoid coil of an electromagnetic actuation coil.

[0042] [Figure 11A] The solenoid connector part after winding is shown.

[0043] [Figure 11B] Shows the solenoid connector section after the IDC pins have been installed.

[0044] [Figure 11C] 10 shows the solenoid connector portion after the winding posts and excess wire have been trimmed.

[0045] [Figure 12A]FIG. 2 is an exploded view showing the solenoid coil and the solenoid coil housing.

[0046] [Figure 12B] 12B shows the same components as in FIG. 12A in an assembled state.

[0047] [Figure 13A] FIG. 12C is another view of the solenoid coil and solenoid coil housing seen in FIG. 12B.

[0048] [Figure 13B] 13B shows the heat stake seen in FIG. 13A after being subjected to a heat staking operation.

[0049] [Figure 14A] 1 shows the components of the overmold assembly.

[0050] [Figure 14B] 1 shows an overmold assembly with an overmold material.

[0051] [Figure 15A] The primary PCB and sensor assembly are shown.

[0052] [Figure 15B] The assembled primary PCB and sensor assembly of FIG. 15A is shown positioned within an electromagnetic actuation coil as indicated by the arrow.

[0053] [Figure 15C] Shows the PWM controller housing cover and overmold assembly.

[0054] [Figure 16A] FIG. 10 is a detailed view of a portion of the drive unit in the differential in an unlocked state.

[0055] [Figure 16B] FIG. 10 is a detailed view showing a portion of the drive unit in the differential in a locked state. DETAILED DESCRIPTION OF THE INVENTION

[0056] Generally, one or more aspects of the present disclosure relate to a differential locking device and a locking mechanism for a differential. The differential locking device disclosed herein has general applicability in many products and industries, including vehicles, robotics, manufacturing, aerospace, and industry. For ease of explanation, the differential locking device will be described in the context of a vehicle, and more specifically, in the context of an electric vehicle. However, the application of the differential locking device disclosed herein is not limited to vehicles and is applicable in many industries.

[0057] The conventional approach to a locked differential is to attach a fixed actuation coil to the rotating differential housing, which creates parasitic drag. This increased parasitic drag reduces the efficiency of the differential. This inefficiency is amplified in electric vehicles where range is at a premium.

[0058] To address some of the problems associated with conventional differential locking devices, the present disclosure describes a differential locking device and its components that has less parasitic drag than conventional differential locking devices.

[0059] FIG. 1 is a diagram of a differential 100 according to an aspect of the present application. In certain embodiments, the differential 100 comprises a differential housing 102 defining an internal cavity. In certain embodiments, the differential 100 further comprises a ring gear 104 and an in-differential drive unit 200 within the differential housing 102. In certain embodiments, the differential housing 102 is fixed to an associated vehicle. In certain embodiments, the ring gear 104 and an in-differential drive unit housing 202 of the in-differential drive unit 200 rotate within the differential housing 102. In certain embodiments, the ring gear 104 and the in-differential drive unit 200 may be mechanically coupled, either directly or indirectly. In certain embodiments, the in-differential drive unit 200 is mechanically coupled, either directly or indirectly, to an axle for driving the wheels of the associated vehicle.

[0060] FIG. 2 is another view of an in-differential drive unit 200. In certain embodiments, the in-differential drive unit 200 includes an in-differential drive unit housing 202. In certain embodiments, within the in-differential drive unit housing 202, the in-differential drive unit 200 includes at least one pinion gear 204, a non-locking side gear 206, and a locking side gear 208. In the illustrated embodiment, the in-differential drive unit housing 202 includes two pinion gears 204, although only one is shown in FIG. 2 for clarity. The pinion gear 204 rotates with a cross shaft 210. The pinion gear 204 may be mechanically coupled and / or interact with the non-locking side gear 206 and the locking side gear 208 to form a mechanical coupling between the non-locking side gear 206 and the locking side gear 208. The non-locking side gear 206 may be coupled to a first axle associated with a first side of the vehicle, and the locking side gear 208 may be coupled to a second axle associated with a second side of the vehicle.

[0061] In certain embodiments, in-differential drive unit 200 further comprises a rotation lock assembly 300. In certain embodiments, rotation lock assembly 300 comprises various components associated with a differential locking device. When actuated, rotation lock assembly 300 locks the position of lock side gear 208 within in-differential drive unit housing 202. When lock side gear 208 is in a fixed position relative to in-differential drive unit housing 202, non-lock side gear 206 is also in a fixed position relative to in-differential drive unit housing 202, and therefore a first axle associated with a first side of the vehicle is locked relative to a second axle associated with a second side of the vehicle.

[0062] In certain embodiments, the rotary lock assembly 300 includes one or more actuation pins 302. In certain embodiments, the actuation pins 302 may be held in place by an actuation pin retaining plate 304. In certain embodiments, the actuation pins 302 and / or the actuation plate 304 may be mechanically coupled, directly or indirectly, to a cam plate 306 such that the actuation pins 302 and / or the actuation pin retaining plate 304 can push or pull the cam plate 306 to actuate the rotary lock assembly 300. In certain embodiments, the cam plate 306 is mechanically coupled to a cam ring 308 such that the cam plate 306 can push or pull the cam ring 308 when the rotary lock assembly 300 is actuated. The actuation pins 302 and / or the actuation plate 304 may be mechanically coupled, directly or indirectly, to the cam ring 308.

[0063] In certain embodiments, the rotary lock assembly 300 includes a return spring 310. In certain embodiments, the return spring 310 biases the differential 100 toward a deactivated or unlocked state. The return spring 310 may be mechanically coupled, directly or indirectly, to the cam ring 308 such that the return spring 310 pushes or pulls the cam ring 308 to bias it toward the unlocked or deactivated state. When the rotary lock assembly 300 is in an activated state, the cam ring 308 engages with the lock side gear 208. When the lock side gear 208 and the cam ring 308 are engaged, their positions are fixed relative to each other, and thus the positions of both the cam ring 308 and the lock side gear 208 are fixed relative to the differential drive unit housing 202.

[0064] FIG. 3 is another view of the differential drive unit 200. As described above, the differential drive unit 200 includes a rotary lock assembly 300. In certain embodiments, the rotary lock assembly 300 includes at least one actuation pin 302 coupled to an actuation pin retaining plate 304. In certain embodiments, the actuation pin 302 includes an end 312. In certain embodiments, the end 312 may include a coupling feature 314. In certain embodiments, the coupling feature 314 is configured to engage with the actuation pin retaining plate 304. For example, in certain embodiments, the coupling feature 314 may be a notch that is engaged by the retaining plate 304. The coupling feature 314 may be a concave feature, a convex feature, or any suitable feature. The actuation pin retaining plate 304 may restrain, retain, lock, or couple the actuation pin 302 in any suitable manner. The actuation pin retaining plate 304 may be fabricated from a single piece. In certain embodiments, actuation pin retaining plate 304 is configured to simultaneously restrain multiple actuation pins 302. In certain embodiments, actuation pin retaining plate 304 includes engagement features 316. In certain embodiments, engagement features 316 are configured to engage with actuation pins 302, and in particular, are configured to engage with coupling features 314 on ends 312 of actuation pins 302.

[0065] 4A shows a more detailed view of the drive unit 200, and in particular a portion of the rotation lock assembly 300 of the drive unit 200. In certain embodiments, when the rotation lock assembly 300 is actuated (placed in a locked state), the cam plate 306 pushes the cam ring 308. In certain embodiments, the cam plate 306 pushes the cam ring 308 toward the lock side gear 208. As the cam ring 308 moves the lock side gear 208, the return spring 310 is compressed. In the actuated position, the cam ring 308 engages with the lock side gear 208. In certain embodiments, the cam ring 308 includes a cam plate locking feature 318 that engages with the lock side gear locking feature 212. In certain embodiments, the cam plate locking feature 318 and / or the lock side gear locking feature 212 are configured as lock face splines.

[0066] 4B is another view of in-differential drive unit 200 of FIG. 4A. In certain embodiments, cam ring 308 includes torque transfer pawl 320. In certain embodiments, when cam ring 308 engages lock side gear 208 in an actuated state, a force acts on cam ring 308. Torque transfer pawl 320 enables the transfer of force between cam ring 308 and in-differential drive unit housing 202. In certain embodiments, torque transfer pawl 320 enables the transfer of force regardless of spin direction.

[0067] FIG. 5 illustrates the in-differential drive unit 200 disposed within the differential housing 102 in an unlocked state. In certain embodiments, the in-differential drive unit 200 includes a rotary lock assembly 300 and a non-rotating lock mechanism 400. In certain embodiments, the rotary lock assembly 300 includes several of the components described above and may further include an attractive moving plate 322, also referred to as a movable member or moving member. The attractive moving plate may be made of a ferromagnetic metal such as iron, cobalt, steel, nickel, manganese, or other materials. In certain embodiments, the attractive moving plate 322 is mechanically coupled to the actuation pin 302, as shown in FIG. 2. When actuated, the attractive moving plate 322 is pulled toward the electromagnetic actuation coil 402 of the non-rotating lock mechanism 400. The electromagnetic actuation coil 402, also referred to as an attractive element, is fixed relative to the differential housing 102 and does not rotate during operation. When not actuated, the attractive moving plate 322 does not contact the electromagnetic actuation coil 402, eliminating potential resistance.

[0068] In certain embodiments, in the unlocked state, there is a gap between the electromagnetic actuation coil 402 and the attractive moving plate 322. In certain embodiments, there is also a gap between the cam ring 308 and the lock side gear 208, and more specifically, there is also a gap between the lock side gear locking feature 212 and the cam plate locking feature 318. In certain embodiments, in the unlocked state, the return spring 310 is in an extended state.

[0069] 6A illustrates the drive unit in differential 200 in a locked state. In the locked state, the attraction moving plate 322 is pulled toward the electromagnetic actuation coil 402. For example, in certain embodiments, the attraction moving plate 322 moves toward the electromagnetic actuation coil 402. In certain embodiments, the attraction moving plate 322 is mechanically coupled to the actuation pins 302, which are mechanically coupled to the actuation pin retaining plate 304, which are mechanically coupled to the cam plate 306, which is mechanically coupled to the cam ring 308. These mechanical connections may be locking, engaging, binding, or simply contacting when pushing or pulling. In certain embodiments, as the attraction moving plate 322 moves toward the electromagnetic actuation coil 402, all of the aforementioned mechanically coupled components also move. It should be understood that not all of the components are required, and components may be omitted. In certain embodiments, when cam ring 308 is pulled toward lock side gear 208, cam plate locking feature 318 is pulled toward lock side gear locking feature 212. cam plate locking feature 318 engages lock side gear locking feature 212. In the locked state, lock side gear 208 is fixed relative to in-differential drive unit housing 202. In certain embodiments, lock side gear 208 is mechanically coupled to non-lock side gear 206 via pinion gear 204. Therefore, when in the locked state, non-lock side gear 206 is also fixed relative to in-differential drive unit housing 202 and lock side gear 208. Therefore, each first side axle associated with a first side of the vehicle and each second side axle associated with a second side of the vehicle are fixed.

[0070] In the locked state, the attraction moving plate 322 is pulled toward the electromagnetic actuation coil 402. For example, in certain embodiments, the attraction moving plate 322 moves toward the electromagnetic actuation coil 402. In certain embodiments, the attraction moving plate 322 is mechanically coupled to the actuation pin 302, which is mechanically coupled to the actuation pin retaining plate 304, which is mechanically coupled to the cam plate 306, which is mechanically coupled to the cam ring 308. These mechanical connections may be locking, engaging, binding, or simply contacting when pushed or pulled. In certain embodiments, as the attraction moving plate 322 moves toward the electromagnetic actuation coil 402, all of the aforementioned mechanically coupled components also move. It should be understood that not all components are required, and components may be omitted. In certain embodiments, as the cam ring 308 is pulled toward the lock side gear 208, the cam plate locking feature 318 is pulled toward the lock side gear locking feature 212. Cam plate locking feature 318 engages lock side gear locking feature 212. In the locked state, lock side gear 208 is fixed relative to in-differential drive unit housing 202. In certain embodiments, lock side gear 208 is mechanically coupled to non-lock side gear 206 via pinion gear 204. Therefore, when in the locked state, non-lock side gear 206 is also fixed relative to in-differential drive unit housing 202 and lock side gear 208. Therefore, each first side axle associated with a first side of the vehicle and each second side axle associated with a second side of the vehicle are fixed.

[0071] FIG. 6B shows a diagram of an alternative embodiment of in-differential drive unit 200 in a locked state. In-differential drive unit 200 may further include an anti-attraction plate 324. Anti-attraction plate 324 may be made of any non-ferrous material, including metals such as stainless steel or aluminum. Anti-attraction plate 324 may also be made of a non-metallic material, such as plastic or ceramic. Anti-attraction plate 324 may be disposed between attraction movement plate 322 and in-differential drive unit housing 202. In some embodiments, magnetic forces acting on attraction movement plate 322 may attract attraction movement plate 322 to in-differential drive unit housing 202. Anti-attraction plate 324 may function to prevent, reduce, or mitigate the attraction force between attraction movement plate 322 and in-differential drive unit housing 202.

[0072] 7A is a diagram of an electromagnetic actuation coil 402. In certain embodiments, the electromagnetic actuation coil 402 comprises a solenoid coil 500, a pulse width modulation (PWM) controller housing 406, and a sensor body 408. In certain embodiments, the solenoid coil 500 may be seated within or connected to the electromagnetic actuation coil 402. FIG. 7B is another diagram of the electromagnetic actuation coil 402 including an integrated connector 410.

[0073] FIG. 8 is a diagram of an electromagnetic actuation coil 402 with cross-sectional lines A, B, and C, where cross-sectional line A corresponds to FIG. 8A, cross-sectional line B corresponds to FIG. 8B, and cross-sectional line C corresponds to FIG. 8C.

[0074] 8A shows a portion of an electromagnetic actuation coil 402. In certain embodiments, the electromagnetic actuation coil 402 includes an IDC pin 412 and a coil wire 414.

[0075] 8B shows a portion of the electromagnetic actuation coil 402, specifically the sensor body 408 and the PWM controller housing 406. In certain embodiments, the electromagnetic actuation coil 402 includes a primary printed circuit board (PCB) 416, a secondary PCB 418, a magnet 420, and a Hall effect IC 422. In certain embodiments, the secondary PCB 418, the magnet 420, and the Hall effect IC 422 are components of a sensor assembly 409.

[0076] 8C shows a portion of the electromagnetic actuation coil 402, specifically the integrated connector 410. In certain embodiments, the electromagnetic actuation coil 402 includes a connector body 424, an O-ring 426, and a connector pin 428.

[0077] 9A shows a solenoid coil housing 450 of the electromagnetic actuation coil 402. In certain embodiments, the solenoid coil housing 450 may be circular in shape. The solenoid coil housing 450 may be configured to constrain, surround, or partially surround the solenoid coil 404. In certain embodiments, the solenoid coil housing 450 includes a first cutout 452 and a second cutout 454.

[0078] 9B, the solenoid coil housing 450 may include tabs 456. In the illustrated embodiment, there are three tabs 456, although more or fewer may be present. The tabs 456 may include mounting holes 458 into which screws may be attached. The solenoid coil housing 450 may also include a number of heat stake pin holes 460.

[0079] FIG. 10 illustrates a solenoid coil 500 of the electromagnetic actuation coil 402. In certain embodiments, the solenoid coil 500 includes a coil bobbin 502. In certain embodiments, the coil bobbin 502 may be circular or shaped to hold a coil winding 504. The coil winding 504 may be infused with a thermoplastic resin or another adhesive or hardening agent. The thermoplastic resin may help hold the multiple turns of the coil winding 504 in place and bond them to one another. The thermoplastic resin may help the turns retain their shape during other manufacturing processes, such as injection molding or overmolding. In certain embodiments, the coil bobbin 502 may further include a heat stake pin 506 configured to couple with a heat stake pin hole 460 in the solenoid coil housing 450. In certain embodiments, the solenoid coil 500 further includes a solenoid connector portion 508.

[0080] 11A-11C show a portion of a solenoid coil 500 during the manufacturing process, specifically the solenoid connector portion 508. FIG. 11A shows the solenoid connector portion 508 after winding. In a particular embodiment, the solenoid connector portion 508 includes a winding post 510 and excess wire 512. FIG. 11B shows the solenoid connector portion 508 after an IDC pin 514 has been installed. FIG. 11C shows the solenoid connector portion 508 after the winding post 510 and excess wire 512 have been trimmed.

[0081] Figure 12A is an exploded view showing solenoid coil 500 and solenoid coil housing 450. In certain embodiments, solenoid coil 500 is partially enclosed by solenoid coil housing 450. Figure 12B shows the same components as Figure 12A, solenoid coil 500 and solenoid coil housing 450, assembled into coil assembly 550.

[0082] Figure 13A is another view of the solenoid coil 500 and solenoid coil housing 450 seen in Figure 12B. In particular, the heat stake pin 506 is shown threaded through the heat stake pin hole 460 prior to the heat stake operation. Figure 13B shows the heat stake pin 506 seen in Figure 13A after undergoing the heat stake operation.

[0083] FIG. 14A shows components of an overmold assembly 600. In certain embodiments, the overmold assembly 600 includes the coil assembly 550, one or more crash limiters 430, and a connector pin 432. FIG. 14B shows the overmold assembly 600 with an overmold material 602. The overmold material 602 may be PA66, GF30, or any other suitable material. The overmold material 602 fills gaps between the solenoid coil housing 450, the solenoid coil 500, and other components of the overmold assembly 600.

[0084] 15A-15C illustrate the assembly of a portion of the electromagnetic actuation coil 402. FIG. 15A illustrates the primary PCB 416 and the sensor assembly 409. In certain embodiments, the sensor assembly 409 may be joined to the primary PCB 416 via a press-fit connection. FIG. 15B illustrates the assembled primary PCB 416 and sensor assembly 409 of FIG. 15A positioned within the electromagnetic actuation coil 402, as indicated by the arrow. More specifically, the primary PCB 416 and sensor assembly 409 are positioned within the overmold assembly 600. FIG. 15C illustrates the PWM controller housing cover 407 in addition to the overmold assembly 600. The arrow in FIG. 15C indicates the orientation of the cover 407 when applied to the electromagnetic actuation coil 402. In certain embodiments, the PWM controller housing cover 407 is held in place by laser welding. In certain embodiments, the laser welding seals the PWM controller housing 406.

[0085] FIG. 16A is a detailed view illustrating one embodiment of the drive unit 200 in the unlocked state, and FIG. 16B is a detailed view illustrating one embodiment of the drive unit 200 in the locked state. The attraction moving plate 322 may be a circular plate including a base plate 326, a first wall portion 328, and a second wall portion 330. The first wall portion 328 may be lower than the second wall portion 330. The electromagnetic actuation coil 402 may include an upper surface 440 facing the inner surface 332 of the base plate 326. The electromagnetic actuation coil 402 may further include an inner ring side surface 442 and an outer ring side surface 444. The inner ring side surface 442 may include a first chamfered transition 446 at an edge of the inner ring side surface 442 adjacent to the upper surface 440. The outer ring side surface 444 may include a second chamfered transition 448 at an edge of the outer ring side surface 444 adjacent to the upper surface 440. The attraction transfer plate 322 is separated from the electromagnetic actuation coil 402 by a gap. The portion of the gap between the top surface 440 and the inner surface 332 may be referred to as the measured gap 350. The measured gap 350 may be approximately 5.25 mm in the unlocked position, or may be 5 mm to 5.5 mm, 4.5 mm to 6 mm, 4 mm to 6.5 mm, or 3 mm to 7.5 mm. The measured gap may be approximately 1.25 mm in the locked position, or may be 1 mm to 1.5 mm, 0.5 mm to 2 mm, or 0.1 mm to 2.5 mm. The attraction transfer plate 322 is separated from the electromagnetic actuation coil 402 so that it does not contact the electromagnetic actuation coil 402 in both the locked and unlocked states.

[0086] In-differential drive unit 200 may further include an anti-attraction plate 324. Anti-attraction plate 324 may be made of any non-ferrous material, including metals such as stainless steel or aluminum. Anti-attraction plate 324 may also be made of non-metallic materials such as plastic or ceramic. Anti-attraction plate 324 may be disposed between attraction movement plate 322 and in-differential drive unit housing 202. In some embodiments, magnetic forces acting on attraction movement plate 322 may attract attraction movement plate 322 to in-differential drive unit housing 202. Anti-attraction plate 324 may function to prevent, reduce, or mitigate attraction forces between attraction movement plate 322 and in-differential drive unit housing 202.

[0087] The foregoing disclosure is not intended to limit the disclosure to the precise form or particular field of use disclosed. It should be understood that the components described in this disclosure may be used outside of a vehicle. The described components may also be applicable to aerospace, robotics, manufacturing equipment, industrial equipment, or other fields. Accordingly, various alternative embodiments and / or modifications to the present disclosure, whether expressly described or implied herein, are contemplated in light of this disclosure. While embodiments of the present disclosure have been described in this manner, those skilled in the art will recognize that changes can be made in form and detail without departing from the scope of the present disclosure. Accordingly, the present disclosure is limited only by the claims.

[0088] In the foregoing specification, the present disclosure has been described with reference to specific embodiments. However, as those skilled in the art will understand, the various embodiments disclosed herein can be modified or embodied in various other ways without departing from the spirit and scope of the present disclosure. Accordingly, this description should be considered illustrative and is for the purpose of teaching those skilled in the art how to make and use various embodiments of the disclosed glove box actuation assembly. It should be understood that the forms of the disclosure shown and described herein should be construed as representative embodiments. Equivalent elements, materials, processes, or steps may be substituted for those typically shown and described herein. Furthermore, certain features of the present disclosure can be utilized independently of the use of other features, as will become apparent to those skilled in the art after having the benefit of this description of the present disclosure. The terms "including," "comprising," "incorporating," "consisting of," "have," "is," and the like, used to describe and claim the present disclosure, are intended to be construed in a non-exclusive manner, i.e., allowing for the presence of items, components, or elements not expressly recited. Also, references to the singular are to be construed as relating to the plural.

[0089] Furthermore, the various embodiments disclosed herein should be construed in an illustrative and explanatory sense, and should not be construed as limiting the present disclosure in any way. All joint references (e.g., attached, fastened, coupled, connected, etc.) are used solely to aid the reader in understanding the present disclosure and do not create limitations with respect to the position, orientation, or use of the systems and / or methods disclosed herein in particular. Accordingly, any joint references should be interpreted broadly. Furthermore, such joint references do not necessarily imply that two elements are directly connected to each other. Furthermore, without limitation, all numerical terms such as "first," "second," "third," "primary," "secondary," "main," or any other conventional and / or numerical terminology should also be construed as identifiers only to aid the reader's comprehension of the various elements, embodiments, variations and / or modifications of the present disclosure, and in particular do not create any limitations regarding the order or preference of any element, embodiment, variation and / or modification relative to or over another element, embodiment, variation and / or modification.

[0090] It will also be understood that one or more of the elements shown in the drawings / figures may be implemented in a more separate or integrated manner, or may be removed or rendered inoperative in certain cases, as may be useful depending on the particular application.

Claims

1. a housing defining an interior cavity; a pair of pinion gears disposed within the internal cavity and rotatably coupled to the housing; a first side gear and a second side gear disposed within the internal cavity in meshing engagement with the pinion gear and rotatably coupled to the housing; a moving member configured to rotate with the housing and move between an engaged position and a disengaged position, the housing being drivingly coupled to the first side gear when the moving member is in the engaged position; and an electromagnetic actuation coil arranged not to rotate with the housing and configured to generate a magnetic field to move the moving member from the disengaged position to the engaged position; Equipped with A differential system wherein the moving member is separated from the electromagnetic actuation coil by a gap when the moving member is in the engaged position and the disengaged position.

2. The moving member is A base plate and A first wall portion; A second wall portion; The differential system of claim 1 , comprising:

3. The differential system of claim 2 wherein said first wall portion is higher than said second wall portion.

4. The differential system of claim 1 , wherein said electromagnetic actuation coil does not contact said moving members.

5. The differential system of claim 4 wherein said electromagnetic actuation coil does not further contact said housing.

6. The differential system of claim 1 , wherein the gap is between 0.1 mm and 2 mm when the moving member is in the engaged position.

7. The differential system of claim 1 , wherein the gap is between 3 mm and 7.5 mm when the moving member is in the disengaged position.

8. 1. A differential locking system, comprising: A plurality of rotating components, the plurality of rotating components comprising: a housing defining an interior cavity; a first side gear and a second side gear disposed within the internal cavity; a moving member that moves between a differential lock position and a differential unlock position; a plurality of rotating components comprising: a plurality of non-rotating components comprising electromagnetically actuated components that do not contact the plurality of rotating components; a plurality of non-rotating components that cause the electromagnetic actuation component to interact with the moving member to move the moving member between the differential locked position and the differential unlocked position; Equipped with When the moving member is in the differential lock position, the first side gear is locked relative to the second side gear; A differential locking system, wherein the moving member is separated from the electromagnetic actuating component by a gap when the moving member is in the differential locked position and the differential unlocked position.

9. 9. The differential locking device system of claim 8, wherein the electromagnetic actuating component comprises a first actuating surface, the moving member comprises a first moving member surface opposite the first actuating surface, and the gap is between the first moving member surface and the first actuating surface.

10. 10. The differential locking system of claim 9, wherein the gap between the electromagnetic actuating component and the moving member is between 6 and 4 mm in the differential unlocked position, and the gap between the electromagnetic actuating component and the moving member is between 2 and 0.1 mm in the differential locked position.

11. 9. The differential locking system of claim 8, wherein said first side gear is coupled to a first drive shaft and said second side gear is coupled to a second drive shaft.

12. the plurality of rotating components further comprising a cam ring coupled to the moving member; 9. The differential locking system of claim 8, wherein said cam ring directly engages said first side gear when said moving member is in said differential locked position.

13. The differential locking device system of claim 8 wherein said moving member is made from a ferromagnetic metal.

14. 1. A differential locking system, comprising: a housing defining an interior cavity, the housing having an axis of rotation; a first gear and a second gear disposed within the internal cavity and rotatable about the rotational axis; a moving member configured to rotate with the housing and move in a direction parallel to the axis of rotation; a suction element configured to move the moving member; Equipped with A differential locking system, wherein the suction element does not contact the moving member when the moving member is in the differential locked position and the differential unlocked position.

15. 15. The differential locking system of claim 14, wherein the attraction element does not contact the housing, the first gear, or the second gear in both the differential locked position and the differential unlocked position.

16. The differential locking device system of claim 14 , wherein the moving member comprises a first wall configured to interact with the suction element.

17. The differential locking device system of claim 16 , wherein the moving member further comprises a second wall configured to interact with the suction element.

18. The differential locking device system of claim 17 wherein said first wall is higher than said second wall.

19. The differential locking system of claim 17 , wherein the first wall and the second wall at least partially surround the suction element when the moving member is in the differential locked position.

20. A differential locking device system as described in claim 1, further comprising an anti-suction plate arranged between the moving member and the housing, the anti-suction plate being configured to reduce the suction force between the moving member and the housing.

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