Lock Plate Structure for Compact Electronic Locking Differentials
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Solution Overview
Problem
Existing electronically actuated locking differentials are bulky and complex, posing challenges in vehicle component packaging as vehicles become more sophisticated.
Innovation Solution
A compact lock plate design for electronically actuated locking differentials featuring near net forged standoffs and a tapered shape, integrated with a biasing mechanism and an electronic actuator, allowing for reduced stress and improved torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional locking differential design is used, then locking functionality is achieved, but device size and complexity increase
Solution Approach 1:
The lock plate integrates multiple functions into a single component: it provides locking engagement through radially spaced teeth, structural support through standoffs, and mounting attachment through integrated features. This consolidation reduces the number of separate parts and simplifies assembly while maintaining effective locking functionality.
Solution Approach 2:
The lock plate serves multiple purposes simultaneously: it engages with differential gear teeth for locking, provides mounting surfaces for standoffs to attach to the gear case, and incorporates features for electronic actuator integration. This multi-functionality reduces overall device complexity while achieving reliable locking.
2Volume of moving object
If compact lock plate design is implemented, then device size is reduced, but torque handling capability may be compromised
Solution Approach 1:
The standoffs feature a tapered geometry that transitions from a larger diameter at the base to a smaller diameter at the tip. This tapered shape optimizes stress distribution by providing a larger base area for load bearing while reducing material usage and overall size. The curved/tapered profile allows the compact standoff to handle torque loads effectively despite its reduced size.
Solution Approach 2:
The lock plate is forged from a single piece of material with optimized grain structure, creating a composite-like internal structure that provides high strength-to-weight ratio. The forging process creates continuous grain flow that enhances torque handling capability while maintaining a compact external geometry.
3Strength
If standoffs are integrally formed with base portion, then manufacturing complexity increases, but structural strength and reliability improve
Solution Approach 1:
The standoffs are integrally formed with the lock plate base portion through a single forging operation, eliminating the need for separate manufacturing and assembly steps. This integration creates continuous material grain structure that enhances structural strength and reliability while the forging process itself is optimized to handle the complex geometry.
Solution Approach 2:
The forging process parameters are optimized to accommodate the integral standoff design, including controlled cooling rates and forging temperatures that ensure proper material flow and grain structure development. These parameter adjustments enable the complex integral geometry to be manufactured reliably while maintaining high structural integrity.
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 design achieves a more compact and robust locking differential with enhanced torque handling capabilities, reduced material costs, and simplified assembly, while maintaining effective locking functionality.
Implementation Method 1
when the stator is energized, the armature is pulled toward the gear case first end such that the lock plate is pushed into locking engagement with the differential gear set
Data Source
Figure 1
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Figure 4~5
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.