Differential Lock Sensor Assembly for Redundant Piston Position Detection
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Solution Overview
Problem
Existing differential systems face challenges in accurately determining the connected or disconnected state of locking differentials, which is crucial for safety-sensitive applications due to limitations in sensing methods used in current electronic actuators.
Innovation Solution
A differential system incorporating an electromagnetic solenoid actuator with a coil assembly and piston, coupled with a multi-sensor position sensing system that includes at least two sensors, such as eddy current sensors and solenoid induction sensors, to precisely detect the piston's position and determine the locked or unlocked state, providing robust measurement and redundancy for reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single sensor is used to detect piston position, then device complexity is reduced, but measurement precision and reliability deteriorate
Solution Approach 1:
The patent applies local quality by using two different types of sensors (eddy current sensor and solenoid induction sensor) with different sensing characteristics to detect the same piston position. Each sensor has its own optimal detection range and characteristics, and by combining them, the system achieves high measurement precision across the entire detection range while maintaining manageable device complexity through targeted sensor selection and placement.
2Reliability
If redundant sensors are implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent replaces mechanical position indication mechanisms with electromagnetic sensing systems. Specifically, it uses eddy current sensors and solenoid induction sensors that detect piston position through electromagnetic fields rather than mechanical contact, thereby improving reliability through non-contact measurement while managing system complexity through electronic integration and signal processing.
Solution Approach 2:
The patent implements beforehand cushioning by using redundant sensor configurations that provide backup detection capabilities. The system is designed with multiple sensors detecting the same parameter so that if one sensor fails or provides inaccurate readings, the other sensors can compensate, ensuring continuous reliable operation of the differential lock system.
3Measurement precision
If multiple sensor types are used, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent applies universality by designing the sensor assembly to serve multiple functions: both sensors detect piston position for primary measurement, while simultaneously providing redundant detection capability and fault tolerance. The control unit integrates signals from both sensors to determine differential lock state, achieving high measurement precision while the modular assembly design maintains ease of manufacture through standardized mounting and electrical connections.
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 solution enhances the accuracy and reliability of differential state detection, ensuring safe and precise operation by mitigating the limitations of individual sensors through redundant measurement, thereby maintaining vehicle condition suitability even if one sensor experiences a fault.
Implementation Method 1
an electromagnetic solenoid actuator that includes a coil assembly and a piston. The piston is configured to selectively induce locking and unlocking of axle shaft speed differentiation in the differential
Implementation Method 2
two or more sensors that are configured to sense a position of the piston
Implementation Method 3
at least another of the at least two sensor units is a solenoid induction sensor
Data Source
AI summary
Methods and systems for a locking differential are provided. The locking differential system includes an electromagnetic solenoid actuator configured to induce locking and unlocking of the differential and a circuit board assembly designed to programmatically control the locking and unlocking functionality. The circuit board assembly includes a multi-sensor sub-assembly having two or more sensor configured to monitor a position of the electromagnetic solenoid actuator.