Differential Carrier Wheel Speed Sensor Integration
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Solution Overview
Problem
Existing wheel speed sensor systems for vehicle drive axles are complex, require lengthy assembly processes, and may not provide accurate measurements due to the use of forged or sintered metal sensor mounting bosses.
Innovation Solution
A wheel speed measurement system that includes a differential side bearing adjustment ring, a tone ring with a radial flange and alternating teeth and gaps, and a retainer ring member, which simplifies installation and enhances accuracy by using a sensor that generates signals based on the tone ring's teeth and gaps, integrated within a sealed environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a forged or sintered metal sensor mounting boss is used, then the sensor can be securely mounted, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent extracts the sensor mounting function from a separate forged or sintered metal boss and integrates it directly into the differential carrier body through a boss formed as part of the differential carrier. This eliminates the need for separate sensor mounting components and reduces assembly complexity while maintaining secure sensor mounting.
Solution Approach 2:
The patent combines the sensor mounting boss with the differential carrier body into a single integrated structure. The boss is formed as an integral part of the differential carrier, merging two previously separate components (mounting boss and carrier) into one, thereby simplifying the assembly process and reducing the number of parts.
2Reliability
If a forged or sintered metal sensor mounting boss is used, then the sensor can be securely mounted, but the welding process and assembly time increase
Solution Approach 1:
The patent removes the need for separate sensor mounting bosses and their associated welding processes by integrating the mounting structure directly into the differential carrier body. This extraction of the mounting function eliminates time-consuming welding operations and reduces overall assembly time.
Solution Approach 2:
The sensor mounting boss is pre-formed as an integral part of the differential carrier body during the carrier manufacturing process, rather than being added later through welding or separate assembly steps. This preliminary integration of the mounting structure eliminates subsequent welding and assembly time.
3Measurement precision
If the sensor is installed at the axle shaft ends nearest to the wheels, then wheel speed can be measured, but the system becomes more complex
Solution Approach 1:
The patent combines the sensor mounting structure with the differential carrier body into an integrated assembly. The sensor is mounted on the differential carrier rather than requiring separate mounting hardware at the axle shaft ends, merging multiple functions into a single location and reducing overall system complexity.
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 system reduces assembly time, eliminates the need for welding, and provides accurate wheel speed measurements, improving the reliability and ease of installation of wheel speed sensors in vehicle drive axles.
Implementation Method 1
The sensor includes a tip portion that is disposed in proximity to the tone ring and generates a sensor signal in relation to the teeth and gaps on the tone ring
Data Source
AI summary
A wheel speed measurement system for a drive axle is provided within a differential assembly. The system includes a differential side bearing adjustment ring configured for adjusting the position of a differential carrier bearing assembly. A tone ring is provided having an inner bore to accommodate a coaxial axle shaft. A retainer ring member is snap-fit between the differential side bearing adjustment ring and the tone ring, permitting relative rotation of the tone ring. Sensors are provided in sensor mounts integrally formed on an exterior of a differential assembly housing.