Axle Bearing Support Strain Sensing for Accurate Torque Measurement
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Solution Overview
Problem
Current mechanical powertrain systems lack effective methods to accurately measure axle torque, which affects efficiency and longevity, and requires additional processing for vehicle operation and implement usage.
Innovation Solution
A torque sensing assembly is integrated into the axle assembly, utilizing strain gages on the bearing support and axle housing to measure strain caused by separation forces between the drive pinion and ring gear, with a controller calculating torque based on detected strain values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a torque sensing assembly is integrated into the axle assembly, then torque measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The torque sensing assembly is merged with the existing axle assembly structure. The bearing support, which is already part of the axle assembly, is used as the mounting structure for the strain gages. This integration approach allows torque measurement functionality to be added without requiring a completely separate measurement system, thereby improving measurement accuracy while minimizing the increase in overall device complexity.
Solution Approach 2:
The bearing support serves multiple functions: it supports the bearing structure and simultaneously acts as the mounting structure for the strain gages used in torque measurement. By making the bearing support multi-functional, the patent reduces the need for additional dedicated torque measurement components, thus improving measurement capability while controlling device complexity.
2Reliability
If strain gages are positioned on the bearing support, then torque measurement reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The bearing support is designed with pre-configured mounting features for the strain gages during the manufacturing process. The bearing support structure is prepared in advance with appropriate attachment points and structural characteristics that facilitate reliable strain gage installation, thereby improving measurement reliability while reducing the complexity of final assembly operations.
3Measurement precision
If multiple strain gages are used to reduce interference from structural loads, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The torque measurement function is segmented into multiple strain gages positioned at different locations on the bearing support. Each strain gage measures strain from a specific direction or location, and by combining the readings from multiple segmented measurement points, the system can distinguish torque-induced strain from structural load-induced strain, thereby improving measurement precision while keeping each individual sensing element relatively simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides accurate torque measurement, reducing interference from vehicle structural loads and enabling efficient powertrain operation, longevity assessment, and proactive maintenance through direct driveline torque monitoring.
Implementation Method 1
A torque sensing assembly is integrated into the axle assembly, utilizing strain gages on the bearing support and axle housing to measure strain caused by separation forces between the drive pinion and ring gear
Data Source
AI summary
A torque sensing assembly of a differential of an axle assembly is shown in the present disclosure. The differential may include a differential housing portion, a drive pinion positioned within the differential housing portion, a ring gear, a carrier, a differential pinion, a first side gear, a second side gear, a first bearing, a first bearing support, and the torque sensing assembly. The first bearing is coupled to the differential housing portion and rotatable with the carrier. The first bearing support is coupled to the differential housing portion and used to support the first bearing. The torque sensing assembly is coupled to the first bearing support and operable to measure a strain thereof resulted from a separation force created between the drive pinion and ring gear.