Locking Differential Solenoid Control in Heat and Vibration
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Solution Overview
Problem
Existing electronic locking differential systems face challenges such as limited programmable capabilities, bulky profiles, and increased likelihood of component degradation due to harsh environmental conditions like heat and vibration, which affect the precision and reliability of the locking mechanism control.
Innovation Solution
A differential system incorporating an electromagnetic solenoid actuator with a coil assembly and a piston for locking and unlocking, along with a circuit board assembly that includes control circuitry and a sensor enclosed in a sealed housing, allowing for compact and reliable control and sensing within the differential, and periodically transitioning to a lower power state to reduce heat and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If electronic actuators are used in the differential system, then actuation speed and durability are improved, but the components are exposed to harsh environmental conditions (heat, vibration, oil) which increases the likelihood of component degradation
Solution Approach 1:
The system is divided into two separate locations: the electromagnetic actuator and sensor are located inside the differential housing where they can quickly respond to locking/unlocking commands, while the controller is located remotely in a protected environment away from harsh conditions. This segmentation allows the speed-critical components to be where they are needed while protecting the sensitive electronics from degradation.
Solution Approach 2:
A communication interface or intermediary system connects the controller (in the protected environment) with the actuator and sensor (in the harsh differential environment). This intermediary enables the controller to send commands and receive status information without being directly exposed to the harsh conditions, thus maintaining both speed and reliability.
2Reliability
If the controller is spaced away from the sensor, then the controller can be protected from harsh environmental conditions, but the controller exhibits a bulky profile which poses packaging challenges
Solution Approach 1:
The controller is positioned in a different spatial dimension or location relative to the differential housing - specifically, in a protected environment outside the differential assembly. This dimensional separation allows the controller to be physically distant from the harsh environment while minimizing the volume occupied within the differential housing itself, as the controller resides in the vehicle's existing electronic control architecture rather than requiring additional space within the differential.
3Ease of manufacture
If control logic is designed at a separate stage from differential manufacture, then manufacturing flexibility is improved, but the precision of control to the locking mechanism decreases
Solution Approach 1:
The sensor positioned adjacent to the locking armature provides real-time feedback on the locking mechanism's position and status. This feedback is transmitted to the controller, which can then adjust control signals to achieve precise locking and unlocking. The feedback loop compensates for any imprecision that may arise from separate manufacturing stages, ensuring accurate control performance.
Solution Approach 2:
The sensor is pre-positioned adjacent to the locking armature during differential assembly, establishing a predetermined sensing relationship before control logic is programmed separately. This preliminary positioning ensures that when the control logic is later developed and integrated, the physical foundation for precise control is already in place, maintaining manufacturing precision despite staged development.
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 enhances the precision and reliability of the locking mechanism, increases packaging efficiency, and extends the longevity of the circuit board assembly by reducing operating temperatures and protecting it from lubricant interference, while maintaining locking functionality.
Implementation Method 1
an electromagnetic solenoid actuator that includes a coil assembly and a piston. The piston is configured to selectively induce locking and unlocking of axle shaft speed differentiation
Data Source
AI summary
Methods and systems for a locking differential are provided. The locking differential system includes an electromagnetic solenoid actuator designed to induce locking and unlocking of the differential and a circuit board assembly designed to programmatically control the locking and unlocking functionality. The circuit board assembly includes a sensor and control circuity enclosed in a continuous sealed enclosure, the sensor extends down the face of a coil assembly in the solenoid.