Electronic Lock Plate With Standoffs for Compact Differentials
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Solution Overview
Problem
Existing electronically actuated locking differentials face challenges in compactness and component packaging, particularly in complex automotive systems, where a more compact design is needed to accommodate increased vehicle complexity.
Innovation Solution
A lock plate with radially spaced teeth and integrally formed standoffs that extend from the base portion, allowing for selective engagement with the differential gear set and utilizing an electronic actuator to switch between unlocked and locked modes, with standoffs configured to reduce stress and accommodate snap rings and armature abutment, enhancing torque transmission and assembly compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional locking differential design is used, then reliable locking function is achieved, but device size and packaging complexity increase
Solution Approach 1:
The patent merges the lock plate with the differential case by integrally forming the lock plate teeth with the case structure. This integration eliminates separate locking components and reduces overall device volume while maintaining reliable locking function. The lock plate is formed as an integral part of the differential case, combining multiple functions into a single structure.
Solution Approach 2:
The differential case is designed to serve multiple functions: it houses the gear set, provides structural support, and incorporates the locking mechanism through integrally formed lock plate teeth. This multi-functionality reduces the number of separate components needed, simplifying packaging and reducing device volume.
2Strength
If lock plate with integrally formed standoffs is used, then structural strength and stress distribution improve, but manufacturing complexity increases
Solution Approach 1:
The standoffs are integrally formed with the lock plate as a single piece, eliminating the need for separate standoff components and their associated fasteners or attachment mechanisms. This integration improves structural strength and stress distribution while the integral formation process is designed to be compatible with existing manufacturing methods.
Solution Approach 2:
The standoff design includes specific geometric parameters such as circumferential spacing, radial positioning, and dimensional proportions that optimize stress distribution. These parameter optimizations enhance structural strength while maintaining manufacturability through standard forming processes.
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 a more compact and robust electronically actuated locking differential with improved unlock performance, reduced material complexity, and compatibility with lower-cost materials, while allowing for efficient locking and unlocking operations.
Implementation Method 1
The electronic actuator is operable between an unlocked first mode where the lock plate does not lockingly engage the differential gear set, and a locked second mode where the when the stator is energized, the armature is pulled toward the gear case first end
Data Source
AI summary
A lock plate for an electronically actuated locking differential is provided. In one example embodiment, the lock plate includes a base portion having a first side and an opposite second side, a plurality of radially spaced teeth extending outwardly from the first side, and a plurality of standoffs extending outwardly from the second side.