Locking Differential Sensing Plate Design for Reliable Lock Detection
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Solution Overview
Problem
Existing vehicle drivetrains with locking differentials lack effective mechanisms to detect and indicate the locking state, which is crucial for ensuring proper functioning and safe vehicle operations.
Innovation Solution
A differential assembly with an electrically activated locking mechanism and a sensor assembly that includes a position sensing plate and a position sensor to determine the locking state, allowing for detection of the differential's locked or unlocked status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a detection structure is added to determine the locking state, then the reliability of the locking mechanism is improved, but the device complexity increases
Solution Approach 1:
A sensing plate is introduced as an intermediary component that translates the axial position of the locking collar into a rotational position that can be easily detected by a sensor. The sensing plate rotates about the sensor axis, converting linear motion of the locking mechanism into rotational motion that the position sensor can measure, thereby improving reliability without significantly increasing complexity
Solution Approach 2:
The patent replaces complex mechanical linkages with a magnetic or optical position sensor that non-contactively measures the position of the sensing plate. This substitution eliminates the need for mechanical contacts and complex transmission mechanisms, reducing device complexity while maintaining detection reliability
2Measurement precision
If the position sensing plate is made non-rotatable with respect to the second housing, then the measurement precision of the axial position is improved, but the device complexity increases
Solution Approach 1:
The patent constrains the sensing plate to rotate only about the sensor axis (one degree of freedom) while preventing rotation about other axes. By defining a specific rotation axis and limiting movement to that dimension, the patent achieves precise measurement without requiring complex multi-axis constraint mechanisms
Solution Approach 2:
The patent extracts the essential function of the sensing plate - to indicate axial position through rotation - and separates it from unnecessary rotational degrees of freedom. By taking out only the required rotational movement about the sensor axis and eliminating other rotations, the design achieves measurement precision with minimal complexity
3Ease of operation
If the ramped collar is located axially between the stator and the position sensing plate, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The patent combines the ramped collar mechanism with the sensing plate assembly into a compact integrated unit. The sensing plate is positioned to be driven directly by the ramped collar's rotation, merging the actuation mechanism and the sensing mechanism into a single coordinated assembly, which simplifies the internal arrangement while maintaining ease of operation
Solution Approach 2:
The sensing plate serves multiple functions: it is driven by the ramped collar to indicate locking state, it rotates about the sensor axis to enable position measurement, and its position directly reflects the axial displacement of the locking collar. This multi-functionality reduces the need for separate components, simplifying the overall device complexity
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
Enables accurate detection and indication of the locking state, ensuring the differential operates correctly and enhances vehicle performance and safety.
Implementation Method 1
a sensor assembly including a position sensing plate and a position sensor, the position sensing plate being coupled to the locking assembly such that operation of the locking assembly between the locked and unlocked positions causes axial movement of the position sensing plate and such that the position sensing plate is non-rotatable with respect to the second housing, and the position sensor is configured to measure an axial position of the position sensing plate
Data Source
AI summary
The present disclosure relates to an electronic locking differential gear mechanism having a lock detection mechanism for sensing and indication of a locked and unlocked state of the locking mechanism. The electronic locking differential gear mechanism includes an electronic stator which, when activated, rotates a ramped collar about an axis of the mechanism. The ramps of the ramped collar axially displace a plurality of push rods, which displace a locking collar and cause it to engage with a locker gear, placing the mechanism in a locked state. A sensor assembly detects the displacement of a sensing plate which is displaced along with the push rods, and thereby senses whether the mechanism is in a locked or unlocked state. Anti-rotation lugs interact with a tab of the sensor assembly to prevent rotation of the sensing plate relative to other components.