Electronically Locking Differential With Integrated Lock Status Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing locking differentials can remain locked even after the electromagnetic coil is switched off, leading to unintended torque traps and a lack of real-time feedback to the driver regarding the differential's state.
Innovation Solution
An electronically locking differential assembly with a lock actuation mechanism and a lock detect mechanism, featuring an armature and stator assembly with an electromagnetic coil, and a switch that changes state to indicate whether the differential is locked or unlocked, providing real-time feedback to the driver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is provided in the differential assembly, then torque transfer control is improved, but the risk of unintended torque trap increases
Solution Approach 1:
A detection mechanism is integrated into the differential assembly to detect whether the locking mechanism is in a locked or unlocked state. This feedback system provides real-time status information to the controller, enabling verification that the differential has properly unlocked when commanded, thereby preventing unintended torque trap conditions while maintaining reliable torque transfer control.
2Loss of information
If a lock detection mechanism is added, then real-time feedback is improved, but device complexity increases
Solution Approach 1:
The detection mechanism is integrated within the existing differential assembly structure rather than being added as a completely separate system. The detection mechanism works in conjunction with the electromagnetic coil and locking mechanism components that are already present, merging multiple functions into a unified assembly. This integration approach provides real-time feedback while minimizing the increase in overall device complexity.
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
Ensures that the differential returns to an unlocked state when the coil is de-energized and provides the driver with immediate assurance of the differential's state, preventing unintended locking and enhancing operational control.
Implementation Method 1
an electromagnetic coil disposed adjacent the ramp plate
Data Source
AI summary
An electronically locking differential assembly constructed in accordance to the present disclosure includes a differential casing, a first and second side gear, a lock actuation assembly and a lock detect mechanism. The first gear defines a first shaft opening configured to provide a first torque transmitting connection with a first output shaft received within the first output shaft opening. The second side gear defines a second output shaft opening configured to provide a second torque transmitting connection with a second output shaft received within the second output shaft opening. The lock actuation mechanism selectively moves between a locked state where the side gears are fixed for concurrent rotation and an unlocked state where the side gears rotate relative to each other. The lock detect mechanism detects whether the lock actuation mechanism is in the locked or unlocked state.