ORC Differential Locking Mechanism for Inertial Engagement Prevention
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Solution Overview
Problem
In vehicle differentials with bi-directional overrunning clutches, the increased inertia of larger components poses challenges in preventing inertial engagements, requiring larger springs and coils, which is problematic for compact designs.
Innovation Solution
A locking mechanism using an armature plate, wave spring, and electromagnetic coil is employed to selectively lock or unlock the rotation of the clutch cam housing relative to the roller cage, allowing for low spring rates and smaller coil sizes, preventing unintended torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the size of the differential components (rollers and roller cage) is increased to handle higher inertia, then the inertia management capability is improved, but the differential size and spring/coil requirements increase
Solution Approach 1:
A locking mechanism is introduced as an intermediary component between the roller cage and the clutch cam housing. This locking mechanism prevents inertial engagements by selectively locking the roller cage to the clutch cam housing when inertial forces exceed a threshold, thereby managing high inertia loads without requiring oversized differential components. The locking mechanism acts as a mediator that enables the system to handle high inertia forces while maintaining a compact differential size.
2Reliability
If larger springs and coils are used to prevent inertial engagements, then the reliability of preventing unintended torque transmission is improved, but the device complexity and size increase
Solution Approach 1:
The locking mechanism serves as an intermediary that simplifies the spring and coil requirements. Instead of relying on large springs and coils to directly prevent inertial engagements, the locking mechanism intermediates by providing a mechanical lock that engages when inertial forces occur, thereby reducing the burden on the spring and coil components and allowing for smaller, less complex designs.
Solution Approach 2:
The locking mechanism replaces part of the mechanical system that would otherwise rely on large springs and coils to manage inertial forces. By introducing a locking mechanism with locking elements that can selectively lock the roller cage to the clutch cam housing, the system substitutes a more efficient mechanical solution that reduces the size and complexity of the spring and coil components.
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 solution effectively manages inertia by allowing for the use of smaller components while preventing inertial engagements, enhancing the compactness and efficiency of differential designs.
Implementation Method 1
The locking mechanism includes an armature plate, a wave spring, and an electromagnetic coil. The electromagnetic coil is positioned to selectively assert a force on the armature plate when activated
Implementation Method 2
The wave spring is positioned to assert a biasing force on the armature plate to selectively engage the clutch cam housing
Data Source
AI summary
An overrunning clutch (ORC) differential is provided that includes a locking mechanism that is configured to lock rotation of a clutch cam housing to a roller cage to retain a centering of each roller in an associated cam roller feature to prevent torque from being communicated between the clutch cam housing and first and second hubs when the locking mechanism is activated.