Inductive Sensor for Differential Locking Gear Position Detection
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Solution Overview
Problem
Conventional axle assemblies with differential mechanisms face challenges in reliably determining the position of locking gears due to rotating and non-rotating components, as well as wear issues, leading to increased complexity and cost.
Innovation Solution
A non-contact sensor apparatus is introduced, comprising a side gear with locking teeth, a locking gear with complementary teeth, a biasing member, an electromagnetic coil, and an inductive sensor to detect the position of the locking gear, reducing complexity and cost while providing accurate position sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact-based sensor mechanisms are used to determine locking gear position, then mechanical connection is established, but wear increases and reliability decreases
Solution Approach 1:
The patent replaces mechanical contact-based position detection with a magnetic field-based inductive sensor system. The sensor detects the position of the locking gear through magnetic coupling without physical contact, eliminating wear from mechanical contact while maintaining reliable position determination for the differential mechanism.
2Measurement precision
If complex mechanical sensing mechanisms are implemented, then position detection capability is improved, but device complexity increases
Solution Approach 1:
The patent simplifies the sensing mechanism by replacing complex mechanical linkages and contact-based sensors with a compact inductive sensor that uses magnetic fields. This non-contact approach achieves accurate locking gear position detection while significantly reducing the complexity of the sensor apparatus and its integration into the differential mechanism.
3Reliability
If traditional position detection methods are used, then mechanical connection is maintained, but cost and weight increase
Solution Approach 1:
The patent eliminates the need for heavy mechanical linkages and contact-based sensing components by implementing an inductive sensor that operates through magnetic coupling. This non-contact magnetic sensing approach achieves reliable position detection while significantly reducing the weight of the sensor apparatus compared to traditional mechanical sensing systems.
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 reliable determination of the differential mechanism's locked or unlocked state, reducing wear and complexity, and improving traction by accurately engaging and disengaging the locking mechanism, thus enhancing torque distribution and vehicle performance.
Implementation Method 1
an electromagnetic coil disposed adjacent the locking gear, and a first inductive sensor for sensing a position of the locking gear
Data Source
AI summary
An axle assembly including a differential case and a side gear having an inboard surface and an outboard surface disposed in the differential case. The side gear outboard surface defines a first plurality of locking teeth. A locking gear having an inboard surface and an outboard surface, wherein the inboard surface includes a second plurality of locking teeth selectively engaged with the first plurality of locking teeth. A biasing member disposed axially between the side gear and the locking gear. An electromagnetic coil disposed adjacent the locking gear. A first inductive sensor for sensing a position of the locking gear.