Electromagnetic Differential Coupler for Uniform Torque
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Solution Overview
Problem
Existing vehicle differentials fail to effectively transmit torque uniformly between wheels when one wheel experiences a surface with a lower coefficient of friction than the other, leading to undesired vehicle performance under certain driving conditions.
Innovation Solution
A vehicle differential with an electromagnetic actuator that includes a housing, an annular gear, fasteners, a coil, and a coupler, where the coupler is fixed to the housing and extends between adjacent fasteners to retain the coil's position, allowing for selective locking and unlocking of the differential to ensure uniform torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a differential allows different wheel turn rates, then the vehicle can accommodate varying wheel speeds during turns and on non-uniform surfaces, but torque cannot be transmitted uniformly to wheels with more traction when one wheel experiences low-friction conditions
Solution Approach 1:
The differential incorporates an electromagnetic actuator that can dynamically change the state of the differential between locked and unlocked conditions. This allows the system to adapt its behavior based on driving conditions, providing both speed differentiation capability and uniform torque transmission when needed, thereby resolving the contradiction between adaptability and reliability.
Solution Approach 2:
The differential locking mechanism changes the mechanical parameter of torque distribution by transitioning between locked and unlocked states. When locked, torque is distributed uniformly; when unlocked, torque distribution allows for speed differentiation. This parameter change enables the system to maintain reliability while preserving adaptability.
2Reliability
If a locking mechanism is provided to lock the differential, then uniform torque transmission is achieved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical locking mechanisms with an electromagnetic actuator system. The electromagnetic actuator uses magnetic fields to engage and disengage the locking mechanism, eliminating the need for complex mechanical linkages, springs, and cam systems traditionally required for differential locking, thereby reducing overall device complexity while maintaining reliable torque transmission.
Solution Approach 2:
The electromagnetic actuator serves multiple functions: it acts as both the locking mechanism and the control element, integrating what would traditionally be separate components. This multi-functionality reduces the number of parts and simplifies the overall differential structure while achieving the desired uniform torque transmission when locked.
3Strength
If fasteners are used to mount the annular gear to the housing, then secure connection is achieved, but the area between adjacent fasteners is limited for additional components
Solution Approach 1:
The coupler is positioned in the radial dimension between the fasteners rather than requiring additional circumferential space. By utilizing the radial dimension and the space between adjacent fasteners in the radial direction, the design accommodates the coupler without compromising gear mounting strength or requiring additional mounting areas.
Solution Approach 2:
The coupler is nested within the space defined by the fastener arrangement, specifically positioned in the area between adjacent fasteners. This nesting approach allows the coupler to occupy the available space efficiently without interfering with the fastener connection between the annular gear and housing, thereby maintaining mounting strength while accommodating additional 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 the differential to adapt to varying wheel conditions by locking the differential when necessary, ensuring torque is applied uniformly to both wheels, thereby improving vehicle performance on uneven surfaces.
Implementation Method 1
a vehicle differential with an electromagnetic actuator that includes a housing, an annular gear, fasteners, a coil, and a coupler
Data Source
AI summary
In at least some implementations, a vehicle differential includes a housing having a mounting flange with multiple openings through the flange, an annular gear mounted to the flange by a plurality of fasteners received through the openings, a coil received radially inwardly of the fasteners, and a coupler. The coupler is fixed to the housing and engaged with the coil to retain the position of the coil relative to the housing, and the coupler extends into an area between adjacent fasteners, where the area is circumferentially between adjacent fasteners and radially overlapped with at least a portion of the adjacent fasteners.