Cohesive Polymer Thrust Plate for Differential Dog Ring Locking
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Solution Overview
Problem
Existing locking power transmitting devices for vehicles face challenges in efficiently transmitting rotary power while preventing speed differentiation between axle shafts, particularly in differential assemblies, where existing solutions do not effectively inhibit relative rotation between components.
Innovation Solution
A power transmitting device incorporating a differential case, a gearset, and a locking mechanism with a first dog ring and a second dog ring, where the second dog ring is non-rotatably but axially slidably coupled to the differential case, and a thrust plate is cohesively bonded to the second dog ring, allowing for selective engagement of the dog teeth to lock the side gear to the differential case, utilizing a solenoid actuator to translate the second dog ring for engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing locking mechanisms are used in differential assemblies, then power transmission is enabled, but relative rotation between components cannot be effectively inhibited
Solution Approach 1:
The locking mechanism is divided into separate dog rings with dog teeth that can engage independently, allowing the locking function to be distributed across multiple components rather than relying on a single complex mechanism
Solution Approach 2:
A thrust plate is introduced as an intermediary component between the actuator and the second dog ring, providing a stable mounting surface and enabling reliable force transmission during the locking operation
2Reliability
If dog teeth engagement is used to lock the differential assembly, then speed differentiation is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The contact surfaces of the dog teeth are designed with specific geometric parameters (first and second radii) that define the engagement characteristics, allowing controlled interaction between mating teeth while accommodating manufacturing tolerances
Solution Approach 2:
The second dog ring combines metal material with a cohesively bonded polymer thrust plate, creating a composite structure that provides both mechanical strength and a stable bonding surface for the polymer component
3Stability of the object's composition
If a thrust plate is cohesively bonded to the second dog ring, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The thrust plate is cohesively bonded to the second dog ring to form an integrated assembly, combining two components into a single stable unit that simplifies the overall structure and reduces the number of separate parts to manage
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 effectively locks the differential assembly, preventing speed differentiation between axle shafts, thereby ensuring efficient power transmission and maintaining vehicle stability by engaging the dog teeth to inhibit relative rotation, enhancing the operational reliability of the drivetrain.
Implementation Method 1
utilizing a solenoid actuator to translate the second dog ring for engagement
Implementation Method 2
a thrust plate is cohesively bonded to the second dog ring
Data Source
AI summary
A power transmitting device that includes a dog ring and a thrust plate. The dog ring is formed of metal and has a plurality of locking features and a set of dog teeth. The locking features are spaced apart around the dog ring and extend in a radial direction. The dog teeth extend in an axial direction. The thrust plate is formed of a polymer and is cohesively bonded to the dog ring.