Electromechanical Differential Lock Actuator with Resilient Coupling
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Solution Overview
Problem
Existing differential locking actuators are bulky, costly, and lack advanced sensing capabilities, leading to inadequate control and safety, particularly in tooth-on-tooth conditions, and they do not integrate well with vehicle onboard systems.
Innovation Solution
A compact electromechanical actuator using an electric motor and lead screw drive assembly with resilient coupling and multiple-state sensing, integrated with vehicle communication systems via a data bus, and featuring manual or automatic failsafe mechanisms for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic systems are used in prior art actuators, then the actuator can provide robust differential locking capability, but the physical size, vehicle cost, and weight significantly increase
Solution Approach 1:
The patent replaces the hydraulic system with an electromechanical system comprising an electric motor and lead screw drive assembly. This substitution eliminates hydraulic fluid, hoses, and pumps while achieving the same differential locking function through direct electromechanical actuation of the actuator pin.
Solution Approach 2:
The patent extracts and removes the hydraulic components from the actuator system, eliminating the source of weight and complexity while retaining the essential locking function through the simplified electromechanical drive system.
2Device complexity
If prior art actuators are designed with basic two-state sensing, then the device complexity is reduced, but the control and safety capabilities are limited
Solution Approach 1:
The patent implements multiple sensors that provide feedback about the actuator's position and the differential lock's engagement state. This feedback enables the control system to detect tooth-on-tooth conditions and adjust operation accordingly, improving safety and control while managing complexity through intelligent sensor integration.
3Device complexity
If prior art actuators lack integration with vehicle onboard systems, then the actuator can operate independently with simpler control infrastructure, but additional separate conductor sets and control components are required
Solution Approach 1:
The patent merges the actuator's control system with the vehicle's existing onboard communication network (CAN bus or LIN bus). This integration eliminates the need for separate control wiring and components, allowing the actuator to communicate with other vehicle systems and be controlled through the vehicle's existing infrastructure.
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 provides improved control and safety by preventing damage in tooth-on-tooth conditions and integrating seamlessly with vehicle systems, ensuring robust and efficient differential locking operations.
Implementation Method 1
an electric motor and lead screw drive assembly for driving an actuator pin
Implementation Method 2
lead screw drive assembly for driving an actuator pin configured to cooperate with the differential lock
Implementation Method 3
The actuator pin may be resiliently coupled to the lead screw to prevent excess force on the actuator pin under otherwise damaging conditions
Data Source
AI summary
An actuator for a differential lock includes an actuator pin that is resiliently coupled to a lead screw to prevent excess force on the actuator pin under otherwise damaging conditions, such as a tooth-on-tooth state of the differential. The actuator may include sensors for sensing the position of a lead screw nut and sensors for sensing the position of the actuating pin to provide improved control by sensing multiple states of the actuator, including a state in which a tooth-on-tooth condition is present in the differential.