Electronic Limited Slip Coupling Bolt-On Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing limited-slip differentials face challenges in mounting and connecting hydraulic couplings due to spatial constraints and complexity, particularly in integrating a hydraulic delivery device with the differential housing.
Innovation Solution
An electronic limited slip coupling system comprising a sleeve, support shaft, hydraulic control unit, clutch assembly, and case, which includes a clutch pack and accumulator housing, allowing for selective interlocking of the sleeve and support shaft, and integration with a differential assembly through splines and fasteners, enabling easy assembly and operation in both front wheel drive and all-wheel drive vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a hydraulic delivery device is located remote from the differential, then it can be separately mounted and maintained, but it becomes challenging to mount the hydraulic delivery device relative to the differential and housing
Solution Approach 1:
The patent combines the hydraulic delivery device with the differential assembly into an integrated unit. The delivery device is mounted directly to the differential housing, and the clutch assembly is positioned to engage with differential components, creating a unified assembly that simplifies mounting while maintaining separate manufacturability.
Solution Approach 2:
The differential housing serves multiple functions: it houses the differential mechanism, provides mounting surfaces for the hydraulic delivery device, and integrates the clutch assembly. This multi-functional design eliminates the need for separate mounting brackets and simplifies the overall assembly process.
2Ease of repair
If the hydraulic coupling is connected separately, then it can be independently serviced, but it becomes challenging to connect the hydraulic coupling between the hydraulic delivery device and the limited-slip differential
Solution Approach 1:
The hydraulic coupling is integrated into the differential assembly with the clutch pack positioned between differential components. The clutch piston connects directly to differential elements, eliminating separate connection hardware and simplifying the connection while allowing the clutch assembly to be serviced as a modular unit.
3Reliability
If a traditional limited-slip differential is used, then it provides traction management, but it lacks electronic control for selective actuation
Solution Approach 1:
The patent replaces traditional mechanical limited-slip mechanisms with an electronically-controlled hydraulic system. The motor-driven pump and control valve assembly enable selective actuation of the clutch pack through electronic signals, providing precise traction management while maintaining mechanical simplicity in the power transmission path.
Solution Approach 2:
The patent uses a hydraulic system with a motor-driven pump, accumulator, and control valve to actuate the clutch pack. Hydraulic fluid is directed to the clutch piston to engage or disengage the limited-slip mechanism, providing smooth and controllable traction management without complex mechanical linkages.
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 system provides a compact, efficient, and easily mountable electronic limited slip differential that can function as an open differential under normal conditions and selectively actuate to manage traction loss by interlocking the clutch assembly, ensuring optimal power distribution between wheels.
Implementation Method 1
The motor is configured to pump fluid into the accumulator chamber of the accumulator housing portion. The clutch assembly receives fluid from the hydraulic control unit.
Data Source
AI summary
An electronic limited slip coupling constructed in accordance to one example of the present disclosure includes a sleeve, a support shaft, a hydraulic control unit, a clutch assembly and a case. The sleeve has a first set of splines projecting inwardly and meshed for engagement with an axle. The support shaft has a second set of splines configured to mesh with a first housing of a differential assembly. The hydraulic control unit has an accumulator housing and a motor. The motor is configured to pump fluid into an accumulator chamber of the accumulator housing. The clutch assembly receives fluid from the hydraulic control unit. The clutch assembly has a clutch pack positioned between a clutch piston and a portion of a clutch basket. The clutch assembly is operable to selectively interlock the sleeve and the support shaft. The case supports the electronic limited slip coupling as an assembled unit.