Electric Axle Differential With Integrated Locking and Separation
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Solution Overview
Problem
Existing differential systems for electric axles face challenges in achieving a compact and economic integration of separation and locking functions, leading to increased complexity, cost, and weight due to the need for costly openings and complex actuators.
Innovation Solution
A differential design featuring a circulating carrier with actuator sleeves providing axially active claw couplings and radially active sliding toothing, allowing for compact integration of separating and locking functions without costly openings, utilizing a magnet-actuated system for actuation and minimizing installation space and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a claw coupling is used at the interface between the driveshaft and lateral gearwheel for separation functionality, then the separating function can be implemented, but the rotation speeds must correlate precisely for re-engagement and additional control systems are required
Solution Approach 1:
The actuator sleeve integrates both the separation actuation and the speed synchronization functions within a single component. The sleeve's own rotation with the driveshaft automatically provides the speed correlation needed for re-engagement, eliminating the need for external control systems to manage clutch synchronization.
Solution Approach 2:
The actuator sleeve performs multiple functions simultaneously: it acts as the separation coupling mechanism, provides speed synchronization through its rotation with the driveshaft, and serves as the interface for re-engagement. This multi-functionality reduces the overall system complexity by consolidating what would otherwise require separate components and control systems.
2Adaptability or versatility
If an external annular structure is used for decoupling in the differential, then the separating function is achieved, but the installation size and weight of the differential increase
Solution Approach 1:
The actuator sleeve is integrated directly into the existing differential structure, merging the separation functionality with the differential housing rather than adding an external annular structure. This integration eliminates the need for additional external components, thereby reducing the overall weight and installation size of the differential assembly.
Solution Approach 2:
The actuator sleeve is positioned concentrically within the differential housing, nesting the separation mechanism inside the existing structure. This nested arrangement allows the separation function to be achieved without increasing the external dimensions or weight of the differential.
3Adaptability or versatility
If complex actuators are arranged in the differential housing for separation functionality, then the locking and separating functions can be implemented, but the device complexity and cost increase
Solution Approach 1:
The complex control and synchronization functions are extracted from the actuator design and replaced by the natural rotation of the actuator sleeve with the driveshaft. This extraction of complexity from the actuator itself simplifies the overall system while maintaining the required locking and separating functions.
Solution Approach 2:
The actuator sleeve automatically provides speed synchronization and re-engagement capability through its own rotation with the driveshaft, eliminating the need for complex external control systems. This self-service approach significantly reduces actuator complexity and cost.
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
This design simplifies the installation of both separating and locking functions within the differential, reducing weight and complexity while maintaining efficient operation, thereby enhancing the overall efficiency and cost-effectiveness of the electric axle system.
Implementation Method 1
utilizing a magnet-actuated system for actuation
Data Source
AI summary
A differential having a circulating carrier with drive gearwheel, at least two planet gearwheels rotatably mounted in the circulating carrier, with lateral gearwheels leading to side shafts of the drive axle of a vehicle and enmeshing with the planet gearwheels, wherein one lateral gearwheel can be connected either to the associated side shaft or to the circulating carrier via a coupling arrangement. The coupling arrangement is located between the circulating carrier and the side shaft and includes an actuator sleeve with an axially active claw coupling towards the lateral gearwheel and a radially active sliding toothing towards the side shaft.