Self-Energizing Locking Differential With Electromagnetic Brake Lock
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Solution Overview
Problem
Existing locking differential assemblies for motor vehicles lack an efficient and reliable mechanism to prevent differential rotation, particularly under varying torque conditions, which can lead to instability and loss of control.
Innovation Solution
A locking differential assembly with an electromagnetically actuated locking mechanism that uses a dog clutch mechanism and a brake plate to generate an opposing torque force, ensuring the differential remains locked without continuous input, utilizing a differential case, output shafts, side gears, differential pin, and an electromagnetic coil to engage a brake disc and create frictional contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is added to prevent differential rotation, then vehicle stability and control are improved, but device complexity increases
Solution Approach 1:
The patent combines the locking mechanism with the existing differential assembly structure, integrating the brake plate, brake disc, and dog clutch components within the differential case. This merging approach adds locking functionality while minimizing overall structural complexity by utilizing the existing differential housing and shafts as part of the locking system.
Solution Approach 2:
The locking mechanism is designed to be self-actuating through the interaction between the drive cam, driven cam, and dog clutch components. When torque is applied to the differential, the drive cam automatically engages the dog clutch locking elements without requiring external actuation, allowing the system to lock itself based on operating conditions.
2Reliability
If an electromagnetic coil and brake plate are used to generate opposing torque force, then the locking mechanism reliability is improved, but use of energy increases
Solution Approach 1:
The electromagnetic coil operates in a periodic manner rather than continuously. The coil is activated only when locking is required, engages the brake plate to create frictional contact with the brake disc, and then deactivates while maintaining the locked position through the mechanical dog clutch mechanism. This periodic operation significantly reduces energy consumption compared to continuous actuation.
Solution Approach 2:
The electromagnetic coil uses friction, typically considered a harmful energy loss, as the primary mechanism for generating the opposing torque force. The brake plate converts electromagnetic energy into frictional contact with the brake disc, creating the necessary torque to engage the locking mechanism. This approach efficiently converts energy into the desired locking action without requiring complex mechanical transmission systems.
3Reliability
If a dog clutch mechanism is used for locking, then the locking effectiveness is improved, but device complexity increases
Solution Approach 1:
The dog clutch locking elements are nested within the differential case structure, with the locking elements positioned between the differential case and the side gears. The drive cam and driven cam mechanisms are integrated within the same space, creating a compact nested arrangement that provides effective locking without adding significant external complexity to the differential assembly.
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 effectively prevents differential rotation, providing stability and maintaining the locked position without continuous input, ensuring bi-stability and improved control by generating a second torque force that opposes the initial torque force, thus enhancing the vehicle's traction and stability.
Implementation Method 1
an electromagnetic coil to engage a brake disc and create frictional contact
Implementation Method 2
The brake plate comes into frictional contact with a brake disc. The friction creates a second torque force which is an opposing torque force to the first torque force
Data Source
AI summary
A locking differential assembly includes a differential case, a first output shaft and a second output shaft. A first side gear is non-rotatably coupled to the first output shaft and a second side gear is non-rotatably coupled to the second output shaft. A differential pin is also included, the differential pin having differential gears. The differential gears are rotatably supported by the differential case and drivingly engaged with the first and second side gears to allow differential rotation thereof. A lock mechanism is actuated when a first torque force is applied to a drive cam and a driven cam. Finally, an electromagnetic coil actuates a brake plate, wherein the brake plate comes into frictional with a brake disc. Furthermore, the electromagnetic coil is discontinuous around the circumference of the brake disc.