Differential Clutch Assembly With Contactless Magnetic Actuation
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Solution Overview
Problem
Existing coupling devices for motor vehicle differentials experience efficiency reduction and wear due to friction between the actuating element and the coupling element during state changes, as they require contact to transition between coupling and decoupling states.
Innovation Solution
The coupling device employs an actuating element that adjusts the coupling element into coupling and decoupling states without physical contact, maintaining a distance between the actuating element and the coupling element to prevent friction, ensuring no speed difference and thus minimizing wear and friction to only occur during state changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the actuating device contacts the coupling element to move it between coupling and decoupling states, then the coupling element can be reliably actuated, but friction occurs between the contact surfaces causing efficiency reduction and wear
Solution Approach 1:
The patent replaces direct mechanical contact between the actuating element and coupling element with a magnetic field-based actuation system. The actuating element generates a magnetic field that acts on the coupling element at a distance, eliminating physical contact and associated friction while maintaining reliable actuation between coupling and decoupling states.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the actuating element and coupling element. This magnetic field mediator transmits the actuating force without requiring direct contact, thereby resolving the contradiction between reliable actuation and friction reduction.
2Ease of operation
If the actuating device contacts the coupling element during operation, then the coupling element can be moved between states, but wear occurs between the contact surfaces
Solution Approach 1:
The patent substitutes mechanical contact-based actuation with magnetic field-based actuation. This replacement eliminates wear between contact surfaces while preserving the ability to move the coupling element between coupling and decoupling states, thereby extending component life.
Solution Approach 2:
The magnetic field serves as an intermediary that enables operation without direct contact. This intermediary mechanism allows the coupling element to be moved between states without the wear that would otherwise occur at contact surfaces, extending the duration of action of the stationary components.
3Productivity
If the coupling element rotates relative to fixed elements during operation, then coupling and decoupling can be achieved, but friction reduces efficiency
Solution Approach 1:
The patent replaces mechanical contact during the coupling/decoupling operation with magnetic field interaction. The actuating element generates a magnetic field that acts on the coupling element during its rotational movement, eliminating friction between contact surfaces and improving overall system efficiency while maintaining productive coupling and decoupling operations.
Data Source
AI summary
Coupling device (1) for a differential (2) of a motor vehicle, has a drive gear (3) and an inner differential carrier (4) which at least partially surrounds at least one bevel differential side gear (5) and at least one bevel differential pinion (6). An actuating device (7) is configured to move a coupling element (8), into a coupling state by the actuating device (7), particularly by means of an actuating element (9), to couple the inner differential carrier (4) with the drive gear (3) and move the coupling element (8) into a decoupling state by the actuating device (7) to decouple the inner differential carrier (4) from the drive gear (3).