Compact E-Locker Differential with Slip Ring Lock Detection
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Solution Overview
Problem
Existing electronically locking differential assemblies face challenges in packaging constraints, safety requirements, and reliability, particularly in electric vehicles, where innovations in design, packaging, and integration are needed.
Innovation Solution
A lockable differential assembly is designed with a lock plate and actuator assembly that includes a stator and armature, along with a slip ring assembly to transmit axial forces and facilitate lock detection, addressing the challenges of packaging and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional locking mechanisms are used in differential assemblies, then structural simplicity is maintained, but packaging efficiency and integration with electric vehicle requirements deteriorate
Solution Approach 1:
The patent combines the actuator assembly, slip ring assembly, lock plate, and detection sensors into an integrated electronic locking differential assembly. The actuator assembly with stator and armature is merged with the locking mechanism, eliminating the need for separate mechanical locking components and achieving compact packaging suitable for electric vehicles.
Solution Approach 2:
The slip ring assembly serves multiple functions: it transmits axial forces between the actuator and lock plate, enables rotational movement, and provides a structure for mounting detection sensors. This multi-functionality reduces the overall number of components needed in the system.
2Reliability
If basic locking functionality is provided, then device simplicity is maintained, but safety and reliability through precise lock detection deteriorate
Solution Approach 1:
The patent incorporates detection sensors that provide feedback on the locking state to the control system. The sensors detect whether the differential assembly is properly locked or unlocked, enabling the control system to verify the actual state and provide feedback to the user interface, thereby enhancing safety and reliability.
Solution Approach 2:
The patent replaces traditional mechanical indicators of locking state with electronic detection sensors. Instead of relying on mechanical position indicators, the system uses sensors to detect the locking state electronically, improving precision and reliability while reducing mechanical complexity.
3Volume of moving object
If compact design is implemented to meet packaging constraints, then packaging efficiency improves, but ease of manufacture and assembly deteriorate
Solution Approach 1:
The patent divides the differential assembly into distinct modular components: actuator assembly, slip ring assembly, lock plate, and detection sensors. Each module can be manufactured and tested independently, then assembled together. This segmentation maintains compact overall dimensions while facilitating easier manufacturing and assembly of individual components.
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 enables efficient electronic locking and unlocking of differential assemblies, improving packaging efficiency, enhancing safety through precise lock detection, and increasing reliability in various vehicle conditions.
Implementation Method 1
the actuator assembly includes a stator and an armature, the actuator assembly configured to be switchable between an energized state and a de-energized state
Implementation Method 2
the slip ring assembly is configured to transmit an axial locking force from the actuator assembly to the lock plate when the actuator assembly is energized
Data Source
AI summary
A lockable differential assembly includes a lock plate that is rotatable about a rotational axis. The differential assembly also includes actuator assembly having a stator and an armature, the actuator assembly being switchable between energized and de-energized states. A radial alignment of the stator is provided based on a piloting feature provided at an outer diameter of the stator housing. A slip ring assembly configured to axially translate based on the locked state or the unlocked state of the differential assembly is provided, including a slip ring that interfaces with the armature at a slip surface, and one or more pins rotationally coupling the slip ring to the lock plate. The slip ring assembly is configured to transmit an axial locking force and an axial return force between the actuator assembly and the lock plate.