A differential

Abstract

A differential lock includes a housing having an annular shape and defining an axis. A coil is positioned in the housing and is movable with the housing along the axis in response to activation of the coil. A force plate is coupled to the housing so that the force plate moves with the housing between the first position and the second position, and so that the force plate is rotatable relative to the housing about the axis.

Description

A DIFFERENTIALCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 677,707 filed July 31, 2024, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] This disclosure is related to a differential lock for differential systems. More specifically, the differential lock is an actuator configured to lock the differential system.SUMMARY

[0003] In some aspects, a differential lock can include a housing having an annular shape and defining an axis. A coil can be positioned in the housing and movable with the housing along the axis in response to activation of the coil. A force plate can be coupled to the housing so that the force plate moves with the housing between the first position and the second position, and the force plate can be rotatable relative to the housing about the axis.

[0004] In some examples, the housing can include a flange and the force plate can include a circumferential groove that receives the flange.

[0005] In some examples, the force plate can have a ring shape with a split between a first end and a second end.

[0006] In some examples, the flange can be defined by a top plate that is coupled to the housing.

[0007] In some examples, the differential lock can further include a lock ring that is moved by the force plate between an engaged position where the lock ring is engaged with a driven member and a disengaged position where the lock ring is disengaged from a driven member.

[0008] In some examples, the lock ring can be translatable along the axis relative to the force plate.

[0009] In some examples, the force plate can define a notch and the lock ring can include a pin that translates within the notch along the axis.

[0010] In some examples, the pin can include a protrusion that is received in the notch.

[0011] In some examples, the pin can be configured to engage with a rotating component of a differential so that the lock ring is rotated by the differential in both the engaged position and the disengaged position.

[0012] In some examples, the rotating component can be a carrier of the differential.

[0013] In some examples, the differential lock can further include a retainer that is coupled to rotate with the carrier, the force plate contacting the carrier in the first position so that the housing is spaced from the retainer by a gap.

[0014] In some examples, the force plate and the retainer can rotate together with the carrier.

[0015] In some aspects, a differential can include a carrier that is rotatable about a carrier axis. A carrier pinion can define a pinion axis. The carrier pinion can be coupled to the carrier such that the carrier pinion rotates with the carrier about the carrier axis and such that the carrier pinion rotates relative to the carrier about the pinion axis. A first axle can be rotatable about the carrier axis, the first axle including a first axle pinion that meshes with the carrier pinion such that first axle is rotatable by the pinion in response to rotation of the carrier. A second axle can be rotatable about the carrier axis, the second axle including a second axle pinion that meshes with the carrier pinion such that second axle is rotatable by the pinion in response to rotation of the carrier. A clutch can be movable along the carrier axis between a first position where the clutch rotationally decouples the first axle from the carrier and a second position where the clutch rotationally couples the first axle to the carrier, the clutch rotating with the carrier about the carrier axis in each of the first position and the second position. An actuator can include an actuator plate that is moveable by the actuator. A force plate can be coupled to the clutch such that the force plate rotates with the clutch about the carrier axis relative to the actuator and such that the clutch is translatable relative to the force plate along the carrier axis, and the force plate can be coupled to the actuator plate such that operation of the actuator moves the force plate to move clutch between the first position and the second position.

[0016] In some examples, the actuator can be sleeved onto an external surface of the carrier.

[0017] In some examples, the actuator can be retained on the carrier by a retainer that is coupled to the carrier, the force plate being moved into contact with the retainer to move the clutch to the first position.

[0018] In some examples, the clutch can be coupled to the carrier via a splined connection.

[0019] In some examples, the splined connection can be formed between a plurality of channels defined in the carrier, which receive a corresponding plurality of pins of the clutch.

[0020] In some examples, the force plate can be sleeved onto the outer surface of the carrier.

[0021] In some examples, the clutch can include a friction plate positioned inside the carrier, the friction plate including first teeth that engage with second teeth on the first axle pinion, and the pins can extend from the friction plate and through a corresponding plurality of openings defined in the carrier to engage with the force plate.

[0022] In some examples, a pin of the plurality of pins can include a protrusion that extends from a contact surface of the pin that engages the force plate, the protrusion extending along the outer surface of the carrier and the protrusion being received in a notch defined by the force plate.

[0023] In some aspects, a method of operating a differential lock to lock and unlock a differential can include applying a current to an actuator. The method can include moving an outer housing of the actuator along an axis relative to an inner housing from a first position to a second position. The method can include translating a force plate along the axis, the force plate rotatable relative to the outer housing about the axis. The method can include moving a clutch between a disengaged position where the clutch is disengaged from a driven member of the differential and an engaged position where the clutch is engaged with the driven member of the differential, the clutch rotating with the force plate and a carrier of the differential in each of the disengaged position and the engaged position.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of embodiments of the invention:

[0025] FIG. 1 is an axonometric view of a differential including a differential lock according to the present disclosure.

[0026] FIG. 2 is an exploded view of the differential and differential lock of FIG. 1.

[0027] FIG. 3 is a cross sectional view of the differential and differential lock of FIG. 1, taken through line III-III, with the differential lock in a first, unlocked position.

[0028] FIG. 4 is a cross sectional view of the differential and differential lock of FIG. 1 , taken through line III-III, with the differential lock in a second, locked position.

[0029] FIG. 5 is an axonometric view of a first side of the differential lock of FIG. 1.

[0030] FIG. 6 is an axonometric view of a second side of the differential lock of FIG. 1.

[0031] FIG. 7 is an axonometric view of a first side of an actuator of the differential lock of FIG. 5.

[0032] FIG. 8 is an axonometric view of a second side of the actuator of the differential lock of FIG. 5.

[0033] FIG. 9 is a cross sectional view of the actuator of the differential lock of FIG.1 taken through line IX-IX.

[0034] FIG. 10 is an axonometric view of a first side of a lock ring of the differential lock of FIG. 1.

[0035] FIG. 11 is an axonometric view of the lock ring of the differential lock of FIG. 1 and an axle pinion of the differential of FIG. 2.

[0036] FIG. 12 is a cross sectional view of a differential carrier and lock ring of FIG. 1. taken through line XIII-XIII.

[0037] FIG. 13 is an axonometric view of a second side of a lock ring of FIG. 10.

[0038] FIG. 14 is an axonometric view of a first side of a force plate of the actuator ofFIG. 7.

[0039] FIG. 15 is an axonometric view of a second side of the force plate of the actuator of FIG. 7.

[0040] FIG. 16 is a cross sectional view of the force plate of FIG. 14 taken through line XVII-XVII.

[0041] FIG. 17 is an axonometric view of a first side of the force plate of FIG. 14 engaging the lock ring of FIG. 10.

[0042] FIG. 18 is an axonometric view of a second side of the force plate of FIG. 14 engaging the lock ring of FIG. 10.

[0043] FIG. 19 is an axonometric view of another example of the force plate of FIG. 14.

[0044] FIG. 20 is a cross sectional view of the force plate of FIG. 19 taken through lineXXII-XXII.

[0045] FIG. 21 is an axonometric view of another example of the force plate of FIG. 16.

[0046] FIG. 22 is a cross sectional view of the force plate of FIG. 21 taken through line XXIV-XXIV.

[0047] FIG. 23 is an axonometric view of a snap ring of the differential lock of FIG. 1.DETAILED DESCRIPTION

[0048] Disclosed embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the disclosed embodiments are shown. Indeed, several different embodiments may be provided and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those skilled in the art.

[0049] The use herein of the term “axial” and variations thereof refers to a direction that extends generally along an axis of symmetry, a central axis, or an elongate direction of a particular component or system. For example, an axially-extending structure of a component may extend generally along a direction that is parallel to an axis of symmetry or an elongate direction of that component. Similarly, the use herein of the term “radial” and variations thereof refers to directions that are generally perpendicular to a corresponding axial direction. For example, a radially extending structure of a component may generally extend at least partly along a direction that is perpendicular to a longitudinal or central axis of that component. The use herein of the term “circumferential” and variations thereof refers to a direction that extends generally around a circumference or periphery of an object, around an axis of symmetry, around a central axis, or around an elongate direction of a particular component or system.

[0050] As also used herein, unless otherwise defined or limited, ordinal numbers are used herein for convenience of reference based generally on the order in which particular components are presented for the relevant part of the disclosure. In this regard, for example, designations such as “first,” “second,” etc., generally indicate only the order in which the relevant component is introduced for discussion and generally do not indicate or require a particular spatial arrangement, functional or structural primacy or order.

[0051] It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listedthereafter and equivalents thereof, as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

[0052] Differential systems are used in drivetrains of motor vehicles to distribute torque from the engine to drive wheels while permitting relative rotation between the wheels. The ability to permit rotation between the wheels is useful when a vehicle turns, as the inside and the outside wheels travel different distances and therefore rotate at different speeds. Without a differential, both wheels rotate at the same speed, which can result in slipping of one of the wheels in some cases. While differential systems improve turning and general driving performance, the differential systems can also cause issues on low-traction environments. If one wheel loses traction, in situations such as driving on ice, mud, or loose dirt, the wheel may spin freely with the other wheel with traction will receive little or no torque. This can result in a loss of forward motion even when one wheel has traction.

[0053] For reference, a differential typically includes a ring gear that engages with a drive shaft. The ring gear is fixed to a carrier such that rotation of the ring gear by the drive shaft causes the carrier to rotate about a carrier axis. A carrier pinion (e.g., a set of carrier pinions) coupled to the carrier such that the carrier pinion rotates with the carrier about the carrier axis. The carrier pinion is also rotatable relative to the carrier about a carrier pinion axis. The carrier pinion engages with each of a first axle (e.g., via a first axle pinion) and a second axle in a first position. The first axle and the second axle are rotatable relative to the carrier. In operation, the carrier pinion can rotate with the carrier about the carrier axis while also rotating relative to the carrier about the carrier pinion axis to transmitting rotation of the carrier to induce rotation of one or both of the first axle and the second axle. Due to the carrier pinion rotating about the carrier pinion axis, the axles can be rotated by the carrier to propel the vehicle, while also allowing the axles to rotate relative to one another.

[0054] However, as mentioned above, in some cases, it may be advantageous to rotationally lock the axles together so that torque is transmitted to all connected drive wheels. In that regard, differential locks are designed to address the limitations of differential systems by rotationally locking the drive wheels together, thereby forcing the wheels to rotate at the samespeed regardless of differences in traction. This allows torque to be applied at all drive wheels. Typical differential locks may be manually engaged by the driver or automatically controlled by onboard electronics based on sensor input.

[0055] Generally, the present disclosure provides systems and methods for a differential lock that is actuator operated. The differential lock may include an actuator configured to move between a first position and a second position to engage and disengage a clutch (e.g., a lock ring) to lock and unlock a differential (e.g., to rotationally lock and unlock a set of axles). The actuator may be an electromagnetic, hydraulic, mechanical, pneumatic, other type of actuator. The actuator may be axially slidable but rotationally fixed in relation to a differential carrier, such that the carrier rotates relative to the actuator. The actuator may move along an axis (e.g., an axis of a drive shaft) of the differential to lock and unlock the differential.

[0056] For example, the actuator can move a clutch relative between a first position and a second position. In the first position the clutch is disengaged from the axle pinion so that the axle is rotatable relative to the carrier and the differential operates in an unlocked or open mode. In the second position, the clutch is moved to couple to the axle pinion first axle pinion or the first axle and fix the axle relative to the carrier (e.g., so that the axle rotates with the carrier). Due to meshing of the first axle pinion with the carrier pinion, the carrier pinion is fixed relative to the carrier so that the carrier pinion does not rotate about the carrier pinion axis. Correspondingly, the meshing of the carrier pinion with the second axle pinion rotationally fixes the second axle relative to the carrier, such that the first axle, the second axle, and the carrier rotate together with the differential in a locked or closed mode.

[0057] In general, the clutch rotates with the carrier in each of the first and the second positions. However, it can be beneficial that carrier can rotate relative to the actuator, as may allow for easy connection of power without rotation of the actuator. In such cases, a slip connection can be provided between the actuator and the clutch to allow the clutch to rotate relative to the actuator.

[0058] FIGS. 1-4 illustrate a non-limiting example of differential 20 that can cause rotation of a first axle 22 and a second axle 24 about an axle axis 25. The differential 20 includes a carrier 26 (e.g., rotating component) that is rotated about a carrier axis 28. The differential defines a differential axis 302. The carrier 26 includes a flange 30 that can receive a drive gear, which engages with a drive shaft to rotate the carrier 26. The differential 20 further includes a first carrierpinion 54 and a second carrier pinion 56 configured to rotate with the carrier 26 about the carrier axis 28. The first carrier pinion 54 and second carrier pinion 56 define a pinion axis 62. The first carrier pinion 54 and the second carrier pinion 56 are also configured to rotate relative to the carrier 26 about the pinion axis 62. The first carrier pinion 54 and second carrier pinion 56 engage with each of the first axle 22 (e.g., a first driven member) and the second axle 24 (e.g., a second driven member). The first axle 22 includes a first axle pinion 50. The second axle 24 includes a second axle pinion 52. The first axle 22 and a second axle 24 are rotatable relative to the carrier 26 about the carrier axis 28. The first carrier pinion 54 and second carrier pinion 56 are configured to induce rotation of one or both of the first axle 22 and the second axle 24. The first axle pinion 50 meshes with the first carrier pinion 54 and second carrier pinion 56 such that the first axle 22 is rotatable by the first carrier pinion 54 and second carrier pinion 56 in response to the rotation of the carrier 26. The second axle pinion 52 meshes with the first carrier pinion 54 and second carrier pinion 56 such that the second axle 24 is rotatable by the first carrier pinion 54 and second carrier pinion 56 in response to the rotation of the carrier 26. When the differential is in an unlocked or open configuration, the first axle 22 and the second axle 24 are rotatable relative to one another. When the differential is in a locked or closed configuration, the first axle 22 and the second axle 24 are rotationally locked such that they rotate together.

[0059] A lock can be used to selectively rotationally lock a first axle and a second axle for corotation. For example, with additional reference to FIGS. 3-6, the differential 20 includes a differential lock 100. In the illustrated example, the differential lock 100 has an annular shape and defining a lock axis 107 (e.g., an axis corresponding to an actuation direction of the differential lock 100). Here, the lock axis 107 is coaxial with the carrier axis 28. The differential lock 100 according to the present disclosure includes a lock ring 40 (e.g., a clutch) that moves between a first position (see FIG. 3) and a second position (see FIG. 4). The lock ring 40 is moveable along the carrier axis 28 between the first position and the second position where the lock ring 40 rotationally decouples the first axle 22 from the carrier 26 and the second position where the lock ring 40 rotationally couples the first axle 22 to the carrier 26, the lock ring 40 rotating with the carrier 26 about the carrier axis 28 in each of the first position and the second position. The lock ring 40 defines a lock ring axis 111. In the first position, the lock ring 40 is disengaged from the first axle 22 so that the differential 20 is unlocked (e.g., open). When unlocked, the first carrier pinion 54 and second carrier pinion 56 are rotatable about the pinion axis 62 to allow relativerotation between the first axle 22 and the second axle 24. In the second position, the lock ring 40 is engaged with the first axle 22 so that the differential 20 is locked (e.g., closed). When locked, first carrier pinion 54 and the second carrier pinion 56 are locked and prevented from rotating about the pinion axis 62 to rotationally fix the first axle 22 and the second axle 24 for corotation. The first carrier pinion 54 and second carrier pinion 56 are locked via the first axle 22, which is rotationally fixed to the carrier 26 via the lock ring 40.

[0060] To move the lock ring 40 between the first position and the second position, the differential lock 100 includes an actuator 105 configured to move a moveable component along the differential axis 302. The actuator 105 has an annular shape and defines an actuator axis 109. The actuator 105 (e.g., a housing thereof) can be sleeved onto an exterior surface of the carrier 26 or may be received inside the carrier 26. In the illustrated non-limiting example, the actuator 105 is a solenoid actuator; however, in other examples the actuator 105 may be in other forms. The differential lock 100 includes a snap ring 110 (e.g., a retainer) configured to retain the actuator 105 on the carrier 26 of the differential 20. The snap ring 110 is coupled to the carrier 26.

[0061] The actuator 105 can move relative to the carrier 26. FIGS. 7-9 illustrate an example of the actuator 105 including housing 410 that includes an inner housing and an outer housing (which may be formed as a single unit as shown in the illustrated example). The actuator 105 further includes coils 425 positioned in the housing 410 (e.g., between the inner housing and the housing 410). Electrical current can be supplied to the coils 425 to generate a magnetic field. The magnetic field interacts with the carrier 26, which can be made of a magnetic material or include a magnet. The housing 410 is moveable along the actuator axis 109 relative to the carrier 26 between a first position and a second position. The housing 410 and the coils 425 move together relative to the carrier 26. Correspondingly, the housing 410 can function as an armature with a moveable coil. A current applied to the coils 425 move the actuator 105 (e.g., the coils 425 and the housing 410) toward the second position in a direction 335. The movement of the actuator 105 can rotationally lock and unlock the axle, as described further below. As current is released from the coils 425, a spring 320 (See FIG. 3) on the first axle pinion 50 can move the actuator 105 back to the first position in the direction 330. In other examples a second current can be applied to the coils 425 to move the actuator 105 back to the first position in the direction 330. In some cases, a bushing 420 can be positioned between the housing 410 and the carrier 26 to reduce friction or wear therebetween. The bushing 420 can be a separate component or a coating that is applied tothe housing 410 (e.g., to the inner housing). The coils 425 may further include a connection port 520 to receive a signal (e.g., a current signal) to actuate the actuator 105. The housing 410 may include an actuator opening 522 that allows the connection port 520 to pass through the housing 410.

[0062] In some cases, an actuator can move a lock ring to engage and disengage an axle (e.g., via an axle pinion). For example, with reference to FIGS. 10 and 13, the lock ring 40 may include first teeth 1815 or other coupling elements (e.g., a friction disk). The first teeth 1815 can be radially aligned along the lock ring 40. The first teeth 1815 are configured to engage the first axle 22 (e.g., via the first axle pinion 50). For example, as described further below, when the actuator 105 moves the lock ring 40 from a first position (e.g., an unlocked position) to a second position (e.g., a locked position), the first teeth 1815 of the lock ring 40 are moved to engage with the first axle pinion 50 causing the lock ring 40 and the first axle pinion 50 to be rotationally locked to the differential axis 302. The lock ring 40 includes peg heads 1805 that face the first axle pinion 50. The lock ring 40 includes a base 1305 with pegs 1310 (e.g., pins) arranged radially along the base 1305. The pegs 1310 extend from a first side 1307 of the base 1305. The pegs 1310 include protrusions 1315 extending away from the base 1305. More specifically, the protrusions 1215 extend from contact surfaces 1317 (e.g., end surfaces) of the pegs 1310. As described further below, the contact surfaces 1317 of the pegs 1310 can be contacted by the actuator 105 or another component moved by the actuator 105 to move the lock ring 40 between the first position and the second position.

[0063] FIG. 11 illustrates an example of the lock ring 40 engaging the first axle pinion 50. In other examples, the lock ring 40 and the first axle pinion 50 may include any other structural configurations to rotationally lock the lock ring 40 and the first axle pinion 50 in the second position. In one example, first axle pinion 50 includes second teeth 2005 that define teeth openings 2010 between each of second teeth 2005. The first teeth 1815 are configured to engage (e.g., mesh with) the second teeth 2005 when the lock ring 40 engages the first axle pinion 50. The first teeth 1815 fit into the teeth openings 2010 when the lock ring 40 is moved in the direction 335. In a working example, when the first teeth 1815 align with the teeth openings 2010 and the lock ring 40 is being forced toward the first axle pinion 50 due to movement of the of the actuator 105, the first teeth 1815 slide into the teeth openings 2010. The engagement of the first teeth 1815 and the second teeth 2005 cause the lock ring 40 and first axle pinion 50 to be rotationally locked relativeto each other along the carrier axis 28. The first axle pinion 50 further includes the spring 320 (See FIG. 3) that moves the lock ring 40 in the direction 330 to the first position after current is released from the actuator 105. As the lock ring 40 is removed from engagement with the first axle pinion 50, the first axle 22 and the second axle 24 are unlocked.

[0064] In some cases, the lock ring can be rotationally coupled to the carrier so that the lock ring is rotated by the carrier in both the engaged position and the disengaged position. For example, as the lock ring is moved to the second position by an actuator, the lock ring is coupled with the carrier such that the rotation of the carrier is locked to the rotation of an axle. FIG. 12 illustrates the lock ring 40 coupled with the carrier 26. The pegs 1310 of the lock ring 40 are received within grooves 64 (e.g., plurality of channels, plurality of openings) of the carrier 26. The pegs 1310 are configured to engage with the carrier 26 so that the lock ring 40 is rotated by the differential 20 in both the engaged position and the disengaged position. When the lock ring 40 is moved from the first position to the second position by the actuator 105 (e.g., via movement of the housing 410), the rotation of the lock ring 40 is locked to the first axle 22 about the carrier axis 28. The carrier 26 is rotatably locked to the lock ring 40 about the carrier axis 28. Correspondingly, a splined connection is formed between the carrier 26 and the lock ring 40, which allows the carrier 26 to transmit rotation to lock ring 40 while allowing translation of the lock ring 40 along the carrier axis 28.

[0065] In some examples, a lock ring can be moved by a force plate. For example, the force plate engages the lock ring as the actuator is actuated to the second position. The force plate is configured to couple and rotationally lock with the lock ring. FIGS 14-16 illustrate a force plate 115 according to one example. For example, the actuator 105 includes the force plate 115, which is coupled to the housing 410 so that the force plate 115 moves with the actuator 105 between the first position and the second position. The force plate 115 is rotatable relative to the housing 410 about the actuator axis 109. That is, the force plate 115 translates along the actuator axis 109 in response to movement of the housing 410 between a first position that disengages the lock ring 40 from the first axle 22 and a second position that engages the lock ring 40. The lock ring 40 is moved by the force plate 115 between an engaged position where the lock ring 40 is engaged with the first axle 22 and a disengaged position where the lock ring 40 is disengaged from the first axle 22. The force plate 115 is positioned inside the housing 410. The force plate 115 may be sleeved on to the outer surface of the carrier 26. The force plate defines a force plate axis 117. The lockring 40 is translatable along the force plate axis 117 relative to the force plate 1 15. The force plate 115 includes a ring 705 axially aligned with force plate axis 117. The ring 705 includes a flange 710 extending radially outward from the ring 705. The force plate 115 includes a shelf 716 extending radially outward from the ring 705.

[0066] The force plate 115 includes a retaining feature 720 (e.g., notch) to secure the lock ring 40 to the force plate 115. The pegs 1310 translate within the retaining feature 720 about the force plate axis 117. The protrusions 1315 of the pegs 1310 are received in the retaining feature 720. In the illustrated non-limiting example, the retaining feature 720 is configured as axial grooves that receive the protrusions 1315 on the lock ring 40. The connection allows torque to be transmitted between the force plate 115 and the lock ring 40 (e.g., for co-rotation), while also allowing for relative movement in axial direction (e.g., translation along the differential axis 302). For example, when the force plate 115 is moved from the first position to the second position to cause corresponding movement of the lock ring 40, the lock ring 40 may encounter a tooth abutment condition where the first teeth 1815 are prevented from meshing with the second teeth 2005. The lock ring 40 can then move to its second position once the tooth abutment is removed. Similarly, when the force plate 115 is moved from the second position to the first position to cause corresponding movement of the lock ring 40, the lock ring 40 may encounter a torque trap condition where the first teeth 1815 are locked with the second teeth 2005 such that the lock ring 40 may be prevented from moving with the actuator 105 to the first position. In such scenarios, the force plate 115 is allowed to move to the first position relative to the lock ring 40. The lock ring 40 can then move to its first position once the torque trap is removed.

[0067] In some examples, the lock ring 40 is coupled to the force plate 115. With reference to FIGS. 3 and 4, the carrier 26 includes a plurality of openings 306 which allows the force plate 115 to receive the lock ring 40. The protrusions 1315 of the lock ring 40 extend from an inner surface 307 of the carrier 26 along an outer surface 309 of the carrier 26 through the openings 306. The protrusions 1315 are received by the retaining feature 720 defined by the force plate 115. In some examples, the pegs 1310 of the lock ring 40 pass through the openings 306 defined in the carrier 26 to engage with the force plate 115.

[0068] FIGS. 17 and 18 illustrate the force plate 115 and lock ring 40 in an engaged position. The force plate 115 and the lock ring 40 are coupled to rotate about the force plate axis 117 in the engaged position. In one example, the shelf 716 includes ridges 805 to increase thedurability of the force plate 115. Each retaining feature 720 aligns with the corresponding protrusion 1315 of the lock ring 40. In the illustrated non-limiting example, the retaining feature 720 are defined as rectangular slots by the ring 705. In one example, the force plate 115 includes a split 725 along the ring 705 and the shelf 716 between a first end and a second end of the ring 705. The split 725 allows the force plate 115 to be compressed to fit the housing 410 into the slot 718 during installation. In one example, the shelf 716 includes indents 730 to reduce stiffness of the force plate 115. In one example, the force plate 115 is made of a non-magnetic material.

[0069] It is appreciated that force plates for the differential lock 100 can be configured differently in other examples. For example, FIGS. 19 and 20 illustrate an alternative example of a force plate 902. The force plate 902 includes a ring 904 and a shelf 905 extending radially outward from the ring 904. The force plate 902 includes a flange 910 extending from the ring 904. The flange 910 and the shelf 905 define a slot 918 configured to receive the housing 410 to couple the force plate 902 to the housing 410. The force plate 902 includes a ridge 915 extending from the ring 904 and the shelf 905. The ridge 915 supports the shelf 905 when force is applied by the actuator 105 on the shelf 905. The force plate 902 includes axial grooves 920 configured to engage protrusions on the lock ring 40. The force plate 902 includes an overlap 925 which allows the force plate 902 to compress to fit the housing 410 into the slot 918 during installation.

[0070] FIGS. 21 and 22 illustrate another alternative example of a force plate 1102. The force plate 1102 includes a ring 1104 and a shelf 1105 extending radially outward from the ring 1104. The force plate 1102 includes a flange 1110 extending from the ring 1104. The flange 1110 and the shelf 1105 define a slot 1118 configured to retain the housing 410 of the actuator 105 to the force plate 1102. The force plate 1102 includes tabs 1115 extending from the shelf 1105. The tabs 1115 include (optional) hooks 1120. The tabs 1115 and the hooks 1120 are configured to engage and secure the lock ring 40 when the force plate 1102 is moved in the direction 335. In one example, the lock ring 40 may include channels that receive and latch the hooks 1120 for the force plate 1102. The force plate 1102 includes an overlap 1125 which allows the force plate 1102 to compress to fit the housing 410 into the slot 1118 during installation.

[0071] In some examples an actuator can include a flange configured to move a force plate when the actuator 105 moves between a first position and a second position. With reference to FIGS. 7-9, the actuator 105 includes a flange configured as a top plate 405 (e.g., actuator plate or anti -rotation bracket) coupled to the housing 410. The top plate 405 is moveable by the actuator105. The top plate 405 moves with the housing 410 when the housing 410 moves in the direction 330 and the direction 335. The slot 718 of the force plate 115 receives the top plate 405 so that the force plate 115 can rotate relative to the top plate 405 about the actuator axis 109. The snap ring 110 prevents the top plate 405 and the housing 410 from moving beyond the snap ring 110 in the direction 330. In one example, the housing 410 and the top plate 405 may be made out of carbon steel. In other examples, the magnetic materials may include but are not limited to iron, nickel, cobalt and ferrites. The magnetic material allows the magnetic field to move the actuator 105 in the direction 335. In the non-actuated state, the actuator 105 can move in the direction 330 towards the snap ring 110 due to a biasing force from the spring 320. In some examples, the top plate 405 may optionally be made out a non-ferromagnetic material. In one example, the force plate 115 is retained on the actuator 105 and may be spaced from the carrier 26 which can result in decreased axial drag. For example, the carrier 26 may define a first diameter and the top plate 405 may define a second diameter. When the force plate 115 is installed on the carrier 26, the force plate 115 expands due to the split 25 to fit the second diameter. In the installed condition, the force plate 115 may define a third diameter that is larger than the first diameter.

[0072] In some cases, the snap ring retains the actuator on the carrier. FIG. 23 illustrates a snap ring 110 according to one embodiment. The snap ring 110 includes a gap 1705 configured to allow the snap ring 110 to expand to be installed on the carrier 26. The carrier 26 may include a groove where the snap ring 110 can be secured to. The snap ring 110 may be made of a third magnetic material. The third magnetic material may be the same as the first magnetic material. For example, the snap ring 110 may be made of carbon steel. In one example, the magnetic material of the snap ring 110 attracts the magnetic material of the top plate 405 and housing 410 in the direction 330. The force plate 115 prevents the top plate 405 from engaging the snap ring 110, such that there is a gap between the top plate 405 and the snap ring 110 that prevents latching to the snap ring 110. This allows for the top plate 405 to be made from a ferromagnetic material. The force plate 115 moves into contact with the snap ring 110 to move the lock ring 40 to the first position. In one example, the force plate 115 may be made of but not limited to plastic. The arrangement of the force plate 115 and snap ring 110 can also reduce wear because the force plate 115 and the snap ring 110 each rotated with the carrier 26. As such, relative rotation between the force plate 115 and snap ring 110 is reduced or prevented.

[0073] The top plate 405 may further include brackets 430 that secure the actuator 105 and prevent the actuator from rotating about the differential axis 302. For example, the brackets 430 may engage a stationary structure such as a differential housing, to prevent the actuator 105 from rotating about the differential axis 302.

[0074] The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

[0075] Additionally, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” “attached,’ and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

[0076] The description of the different advantageous embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different advantageous embodiments may provide different advantages as compared to other advantageous embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

CLAIMSWhat is claimed is:

1. A differential lock comprising: a housing having an annular shape and defining an axis; a coil positioned in the housing and movable with the housing along the axis in response to activation of the coil; a force plate coupled to the housing so that the force plate moves with the housing between the first position and the second position, and the force plate rotatable relative to the housing about the axis.

2. The differential lock of claim 1 , wherein the housing includes a flange and the force plate includes a circumferential groove that receives the flange.

3. The differential lock of claim 2, wherein the force plate has a ring shape with a split between a first end and a second end.

4. The differential lock of claim 2, wherein the flange is defined by a top plate that is coupled to the housing.

5. The differential lock of claim 1, further comprising a lock ring that is moved by the force plate between an engaged position where the lock ring is engaged with a driven member and a disengaged position where the lock ring is disengaged from a driven member.

6. The differential lock of claim 5, wherein the lock ring is translatable along the axis relative to the force plate.

7. The differential lock of claim 5, wherein the force plate defines a notch and the lock ring includes a pin that translates within the notch along the axis.

8. The differential lock of claim 7, wherein the pin includes a protrusion that is received in the notch.

9. The differential lock of claim 7, wherein the pin is configured to engage with a rotating component of a differential so that the lock ring is rotated by the differential in both the engaged position and the disengaged position.

10. The differential lock of claim 9, wherein the rotating component is a carrier of the differential.

11. The differential lock of claim 10 further comprising a retainer that is coupled to rotate with the carrier, the force plate contacting the carrier in the first position so that the housing is spaced from the retainer by a gap.

12. The differential lock of claim 10, wherein the force plate and the retainer rotate together with the carrier.

13. A differential comprising: a carrier that is rotatable about a carrier axis; a carrier pinion defining a pinion axis, the carrier pinion coupled to the carrier such that the carrier pinion rotates with the carrier about the carrier axis and such that the carrier pinion rotates relative to the carrier about the pinion axis; a first axle that is rotatable about the carrier axis, the first axle including a first axle pinion that meshes with the carrier pinion such that first axle is rotatable by the pinion in response to rotation of the carrier; a second axle that is rotatable about the carrier axis, the second axle including a second axle pinion that meshes with the carrier pinion such that second axle is rotatable by the pinion in response to rotation of the carrier; a clutch that is movable along the carrier axis between a first position where the clutch rotationally decouples the first axle from the carrier and a second position where the clutch rotationally couples the first axle to the carrier, the clutch rotating with the carrier about the carrier axis in each of the first position and the second position; an actuator including an actuator plate that is moveable by the actuator; and a force plate coupled to the clutch such that the force plate rotates with the clutch about the carrier axis relative to the actuator and such that the clutch is translatable relative to the force plate along the carrier axis, and the force plate coupled to the actuator plate such that operation of the actuator moves the force plate to move clutch between the first position and the second position.

14. The differential of claim 13, wherein the actuator is sleeved onto an external surface of the carrier.

15. The differential of claim 14, wherein the actuator is retained on the carrier by a retainer that is coupled to the carrier, the force plate being moved into contact with the retainer to move the clutch to the first position.

16. The differential of claim 13, wherein the clutch is coupled to the carrier via a splined connection.

17. The differential of claim 16, wherein the splined connection is formed between a plurality of channels defined in the carrier, which receive a corresponding plurality of pins of the clutch.

18. The differential of claim 16, wherein the force plate is sleeved onto the outer surface of the carrier.

19. The differential of claim 18, wherein the clutch includes a friction plate positioned inside the carrier, the friction plate including first teeth that engage with second teeth on the first axle pinion, and wherein the pins from the friction plate and through a corresponding plurality of openings defined in the carrier to engage with the force plate.

20. The differential of claim 18, wherein a pin of the plurality of pins includes a protrusion that extends from a contact surface of the pin that engages the force plate, the protrusion extending along the outer surface of the carrier and the protrusion being received in a notch defined by the force plate.

21. A method of operating a differential lock to lock and unlock a differential, the method comprising: applying a current to an actuator; moving an outer housing of the actuator along an axis relative to an inner housing from a first position to a second position; translating a force plate along the axis, the force plate rotatable relative to the outer housing about the axis; moving a clutch between a disengaged position where the clutch is disengaged from a driven member of the differential and an engaged position where the clutch is engaged with the driven member of the differential, the clutch rotating with the force plate and a carrier of the differential in each of the disengaged position and the engaged position.

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