Locking Differential Dog Clutch With Cam-Assisted Electromagnet
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Solution Overview
Problem
Locking differentials in vehicle drive lines face challenges in managing torque transmission, requiring oversized actuators to counteract vector components that can lead to increased space requirements and complexity, especially when integrating electromagnetic actuators and cam mechanisms.
Innovation Solution
An electronic locking differential design incorporating a carrier, differential gearset, first and second dog members, a cam mechanism, a spring, and an electromagnet, where the electromagnet creates a magnetic field to move the second dog member and the cam mechanism assists in maintaining engagement under torque thresholds, reducing the need for large actuators and space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a relatively powerful actuator is used to move the second dog member, then the actuator can overcome the vector components and hold the second dog member in the second position, but the actuator becomes oversized and requires more space
Solution Approach 1:
The cam mechanism acts as a mechanical counterweight system that generates forces opposing the vector components acting on the dog clutch teeth. The cam profile is designed to produce canceling forces that reduce the load on the electromagnet, allowing a smaller actuator to maintain the second dog member in the engaged position without requiring an oversized device.
Solution Approach 2:
The cam mechanism serves as an intermediary between the vector components and the electromagnet. It translates and modifies the force requirements, converting the need for large direct holding forces into a system where the cam generates counteracting forces that reduce the electromagnet's burden, enabling compact actuator design.
2Reliability
If a cam mechanism is integrated into the second dog member and carrier to generate canceling forces, then the need for oversized actuators is reduced, but a relatively large space is required for the integration of the actuator and cam mechanism
Solution Approach 1:
The cam mechanism is nested within the existing structural space of the carrier and second dog member assembly. The cam is positioned within the carrier's interior cavity, utilizing otherwise unused space. The electromagnet is disposed within the annular pocket formed by the carrier's circumferentially extending projection, creating a compact nested arrangement that minimizes the overall footprint.
Solution Approach 2:
The design utilizes the annular pocket dimension created by the circumferentially extending projection of the carrier. By placing the electromagnet within this annular space rather than requiring additional external space, the design effectively uses a different spatial dimension (radial depth of the annular pocket) to accommodate the actuator, reducing the overall area requirement.
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
This configuration allows for a more compact and efficient locking differential that effectively manages torque transmission without the need for oversized actuators, enhancing operational efficiency and reducing space requirements.
Implementation Method 1
The electromagnet is operable in an energized state to create a magnetic field that draws the second frustoconical surface on the pole piece toward the first frustoconical surface to correspondingly move the second dog member toward the second position.
Data Source
AI summary
An electronic locking differential that includes a movable electromagnet to selectively operate a dog clutch for locking a side gear to a carrier. The dog clutch includes a dog member having a plurality of legs that extend through leg apertures in the carrier. A cam mechanism is employed on the legs and the carrier to generate and apply a force to the dog member to maintain the dog member in an engaged position when torque is transmitted through the cam mechanism. The carrier is configured with an annular rib that surrounds a pocket. The annular rib has a frustoconical shape that matches that of a pole piece on the electromagnet. The electromagnet is received into the pocket when the electromagnet is operated and the dog member is in its engaged position.