Electronic Locking Differential with Direct State Detection
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Solution Overview
Problem
Existing electronic locking differentials in axle assemblies are susceptible to improvements in terms of operational efficiency and reliability, particularly in ensuring secure engagement of locking mechanisms.
Innovation Solution
The axle assembly incorporates a locking device with a first and second dog ring, a return spring, a thrust member, and an actuator, where the actuator moves the thrust member to engage the teeth of the dog rings, inhibiting relative rotation between the second side gear and the differential case, thereby enhancing locking stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electromagnetic actuator is used to couple the side gear to the differential case, then the differential can operate in a fully locked condition, but the system becomes susceptible to reliability issues in ensuring secure engagement of the locking mechanism
Solution Approach 1:
A sensor detects the position of the plunger and generates a sensor position signal. When the plunger is in the retracted position, the sensor signal indicates that the locking dogs are engaged, providing feedback confirmation of the locked state to the control system.
Solution Approach 2:
A plunger acts as an intermediary component between the electromagnetic actuator and the locking dogs. The plunger translates the electromagnetic actuator's motion into precise engagement of the locking dogs with the dogs in the side gear, ensuring reliable locking while simplifying the overall mechanism.
2Stability of the object's composition
If the actuator moves the plunger to push the thrust member and second dog toward the first dog, then the teeth and mating teeth engage to inhibit relative rotation, but the device complexity increases
Solution Approach 1:
The plunger, thrust member, and second dog are fixedly coupled to one another, merging these components into a single integrated assembly. This reduces the number of separate parts and simplifies the locking device structure while maintaining stable locking through the engaged teeth of the dogs.
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 ensures robust locking of the differential assembly, preventing speed differentiation between axle shafts and improving operational reliability by ensuring secure engagement of the locking mechanism.
Implementation Method 1
The return spring biases at least one of the first and second dogs in a direction so that the teeth and the mating teeth are not engaged to one another
Implementation Method 2
The actuator is operable in a returned position, which permits the return spring to maintain the teeth and the mating teeth in a de-coupled condition, and an extended position in which the actuator moves the plunger to push the thrust member and the second dog toward the first dog
Data Source
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AI summary
An axle assembly with an electronic locking differential that employs a locking mechanism having components that are fixed to one another along an axis such that they co-translate with one another when the actuator that effects the locking and unlocking of the differential is operated. A method for assembling a differential is also provided.