Differential Locking Structure With Bi-Stable Electromagnetic Clutch
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Solution Overview
Problem
Automobile differentials struggle to provide sufficient traction when one wheel slips on uneven or muddy surfaces due to equal torque distribution, leading to inadequate ability to escape such situations.
Innovation Solution
A bi-stable electromagnetic clutch is integrated into the differential's output axle shaft, featuring a movable and fixed locking disc with engaging teeth, allowing for controlled locking of the axle shaft and differential housing to achieve synchronized rotational speed and torque, utilizing a bi-stable electromagnetic clutch that can engage or disengage based on magnetic or spring states, and includes a position sensor for monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional differential mechanism is used to enable wheels to rotate at different speeds, then the differential can balance output torque during turning or on uneven roads, but the differential cannot provide sufficient traction when one wheel slips on muddy surfaces
Solution Approach 1:
The locking structure transitions between locked and unlocked states dynamically based on driving conditions. The electromagnetic clutch enables the locking disc to move axially, engaging or disengaging the face teeth with the output axle shaft, allowing the system to adapt between differential action and locked differential action as needed
Solution Approach 2:
The system changes the torque distribution parameter from equal torque distribution (unlocked state) to locked torque distribution (locked state). The electromagnetic clutch controls the axial position of the locking disc, changing the engagement state of the face teeth, thereby changing the torque transmission parameter from differential to locked
2Reliability
If a locking mechanism is added to the differential to improve traction, then the vehicle can get out of muddy situations, but the device complexity increases
Solution Approach 1:
The locking function is merged with the existing differential structure. The locking disc is sleeved on the output axle shaft within the differential housing, and the electromagnetic clutch is integrated into the differential assembly, combining the locking mechanism with the differential mechanism in a compact arrangement
Solution Approach 2:
The electromagnetic clutch replaces complex mechanical actuation systems. Instead of using mechanical linkages, cables, or hydraulic systems to control the locking mechanism, an electromagnetic field is used to actuate the locking disc axially, simplifying the control system while maintaining reliability
3Ease of operation
If an electromagnetic clutch is used to control the locking mechanism, then the locking can be controlled precisely, but the manufacturing complexity and cost increase
Solution Approach 1:
The electromagnetic clutch serves multiple functions: it acts as both the actuator for the locking mechanism and the control element for torque transmission. The same electromagnetic clutch that engages the locking disc also controls the engagement of the face teeth, eliminating the need for separate control mechanisms and reducing manufacturing 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 solution enhances traction by ensuring equal rotational speed and torque across both wheels, providing a compact, controllable, and long-lasting locking mechanism that improves the vehicle's ability to navigate challenging terrain.
Implementation Method 1
the electromagnetic clutch drives the movable locking disc to move axially after being energized
Implementation Method 2
the armature disc carries with a number of magnets, the yoke carries with a number of cylindrical iron
Implementation Method 3
the bi-stable electromagnetic clutch is self-held by springs for a disengaged state or a magnet for an engaged state
Data Source
AI summary
The present disclosure discloses a locking structure of a differential. The locking structure comprises a bi-stable electromagnetic clutch sleeved on an output axle shaft on one side of the differential. The bi-stable electromagnetic clutch comprises a movable locking disc and a fixed locking disc; the fixed locking disc is fixedly connected to a differential housing, and the movable locking disc and the fixed locking disc have face teeth that can engage with each other. The movable locking disc is sleeved on the output axle shaft, the bi-stable electromagnetic clutch drives the movable locking disc to move axially after being energized, the output axle shaft and the differential housing are locked when the movable face teeth engaged with the fixed face teeth so that the output axle shaft on either side of the differential and the differential housing have a same rotational speed and output torque.