Bi-Stable Solenoid Actuator for Power-Free Differential Locking
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Solution Overview
Problem
Existing systems for locking differential gears require continuous electric power to maintain the locked state, which depletes battery charge and can lead to mechanical binding issues.
Innovation Solution
A bi-stable solenoid actuator with an annular steel housing, winding, permanent magnets, and a return spring, allowing the differential to be locked without continuous power application by leveraging magnetic fields to maintain the locked state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous electric power is applied to a solenoid to lock the differential, then the differential locking reliability is improved, but the battery charge is depleted
Solution Approach 1:
The solenoid is actuated periodically or intermittently rather than continuously. The bi-stable mechanism maintains the locked state after brief solenoid activation, allowing power to be cut during maintenance while preserving the locking function. This reduces energy consumption significantly compared to continuous power application.
Solution Approach 2:
The bi-stable solenoid mechanism serves itself by maintaining its state without external power. Once activated, the mechanical bi-stable structure holds the differential locked or unlocked without requiring continuous electrical power, making the system self-sustaining in its operational states.
2Reliability
If continuous electric power is applied to a solenoid to maintain differential locking, then the locked state is maintained reliably, but the system complexity increases due to continuous power supply requirements
Solution Approach 1:
The bi-stable solenoid automatically maintains its state without external intervention or continuous power. The mechanical design inherently preserves the locked or unlocked position through its bi-stable structure, eliminating the need for complex continuous power management systems.
3Ease of operation
If a conventional solenoid is used to lock the differential, then the locking function is achieved, but mechanical binding issues occur due to non-uniform force distribution
Solution Approach 1:
The solenoid employs an annular (ring-shaped) design with curved geometry instead of a linear structure. This annular configuration distributes the magnetic and mechanical forces uniformly around the differential locking mechanism, preventing localized stress concentrations that cause mechanical binding.
Solution Approach 2:
The annular solenoid creates different local magnetic field zones around the locking mechanism, with each section contributing to uniform overall force distribution. This localized force application throughout the annular path ensures even engagement without binding.
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
The bi-stable solenoid actuator maintains the differential gear set in a locked or unlocked state without continuous power, reducing power consumption and minimizing mechanical binding.
Implementation Method 1
permanent magnets and a steel housing and steel cover allow a magnetic field to be sufficient to hold the differential set of gears locked
Implementation Method 2
a winding wrapped around an annular winding carrier
Data Source
AI summary
Methods and systems for fabricating and operating a bi-stable solenoid actuator are described. The system may include permanent magnets that are arranged in a circle. The permanent magnets may provide sufficient force to maintain a differential in a locked state when electric power is not applied to a coil that operates as an electro-magnet.